How to remove the top of the engine on a ZXR400? PICS NOW!

Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

Hi I need to look at the valves and cylinders, how hard is it to get it all off so I can see them. Think there is something in there or it's dropped a valve, long story but how to get it off, the manuals a bit crap...
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Barry_M2 · World Chat Champion Joined: 09 Sep 2004 Karma :

I done this years ago on a L model ZXR400. It's all really tight around that area. From what I remember, its tank off, carbs and airbox off, plug caps out then rocker cover off.

But, when you come to take the rocker cover off I remember it being a real pain to get it over the cam wheels as its so tight against the frame. But I did manage it.
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Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

Yeah I am as far as the rocker cover, now theres two things attached to the frame which are something to do with the electrics.

Did you take them off or unbolt it with them on, cause they are in the way.
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Barry_M2 · World Chat Champion Joined: 09 Sep 2004 Karma :

I think you must mean the coils?

Yeah, unbolt and move them. You'll find that the cam cover is a real pain to get off, it just seems to hit everthing just as you think your getting somewhere!
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Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

OK for the 4 bolts on the rocker cover, will they need to be bolted back in with a torque wrench, dad says they might have to be?

At the moment I can undo them without much effort using a spanner. But this bike been messed about with in the past
(previous owner) so that could be wrong.
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Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

Ok he meant the bolts holding down the cams which need to be torque wrenched, I see the torques in the manual.

Can I use any silicon sealant or does it have to be Kawasaki branded? any I guess?

Anyone got any tips for getting this rocker cover off, it's a pain!

This my first time messing around with engines sorry for all the questions!
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Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

I have takent the rocker cover off with the engine in the frame, but if you suspect a dropped valve and are intending to take the head off I would be tempted to drop the engine out.

You should not need a torque wrench to undo the rocker cover bolts.

All the best

Keith
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Barry_M2 · World Chat Champion Joined: 09 Sep 2004 Karma :

Yoshi - What makes you suspect its a dropped valve?
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Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

OK got the rocker cover off now, my dad's friend is gonna help me he is a bit more mechanical. Also he got a torque wrench to lend me.

I'm going to study the manual, see how much work it looks like to get the head off.

How much effort is it to drop the engine out?

I don't know if its a dropped valve but basically when I took the carbs off (to put restrictors in) there was a bolt sitting on an inlet valve (gave me a surprise) so I removed it, put it back together and it made a horrible noise when i tried starting it, took restrictors out, same thing, so I'm thinking if that bolt was in there what else was in there etc Confused

it could have damaged cylinder/piston/valve?

Plus I want to learn this kind of thing, after this I am going to buy a cheap bike to strip down/mess around with which I don't have to worry about messing up.
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Finglonga · World Chat Champion Joined: 27 Jul 2004 Karma :

I can see this ending in tears, are you sure you are capable of a stripdown like this? If not don't do it, bite the bullet and get it into a garage or it could cost alot to put things right.
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Barry_M2 · World Chat Champion Joined: 09 Sep 2004 Karma :

edd · Nearly there... Joined: 06 Jul 2005 Karma :

defo fix it yourself, you might need a few tools and bent valves can sometimes be a real bitch to sort out but you will learn from it. Thumbs Up

Taking the head off your bike will mean you need a new head gasket which arent cheap, and you will want to be replacing your base gasket if it is held on with the same studs (or infact if a zxr 400 has a seperate block from the cases im unfamiliar with them)
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Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

I would be a bit worried about where the bolt came from and how many others had followed it. Only ones I can think of are for holding the airbox onto the carbs on a ZXR400, and if one of those was loose you would need to be exceptionally lucky for it to get that far without dropping into the engine properly.

If you remove the cylinder head then you will definatly have to replace the head gasket.

The rocker cover gasket is probably a rubber one and can be reused as long as it is not damaged.

All the best

Keith
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veeeffarr · Super Spammer Joined: 22 Jul 2004 Karma :

Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

Can you post a pic of the bolt? Pretty much any M6 or smaller bolt would likely get through the carb and trash the engine within a very short space of time with the engine running.

All the best

Keith
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ram_doom · World Chat Champion Joined: 25 Mar 2006 Karma :

Paddy Blake · World Chat Champion Joined: 29 Jun 2006 Karma :

Remember to losen and tighten the head bolts a little at a time and
losen from outside to inside in a x. Just check the manual for this
or you could warp the head. Thumbs Up

Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

It says in the manual "Before removing the cam chain tensioner, position the crankshaft at #1, 4 piston TDC"

I kind of understand, but what does TDC mean? It wants me to move the crankshaft so the TDC mark in inline with the Timing mark?

Also does the cam chain need to come off or just the tensioner??

And what does the manual mean by damper rubber, says I need to remove it?

Thanks for all advice, also will put up a pic of where that bolt was tomorrow been busy today Laughing

also my dads friend said about loosening/tightening in the X shape etc but still thanks.
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ram_doom · World Chat Champion Joined: 25 Mar 2006 Karma :

TDC - Top Dead Center

When a piston is at its highest point, furthest away from the crankshaft Thumbs Up

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Kickstart · The Oracle Joined: 04 Feb 2002 Karma :

Hi

TDC as above.

The cam chain will need to be unhooked from the cams, and to do that you will need to remove the tensioner.

To be honest from your comments so far you are displaying a lack of knowledge that could get expensive when taking the head off. I would suggest doing some reading up of generic engine books before going any further (eg, might not tell you anything about the ZXR engine but reading a copy of "How To Modify Your Mini" by David Vizard will teach you a lot about the basics of an engine).

All the best

Keith
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Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

OK thanks.

I am inexperienced with engines, but it'll remain that way unless I get stuck in and have a go. I won't do anything that I don't think I can undo plus I have someone helping me. Worst case I just take it to the garage and let them fix it, might cost a bit though.

Thanks,
Matt
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Yoshi · Traffic Copper Joined: 05 Jul 2005 Karma :

To get it to TDC 1,4 Do I use a spanner to line them up or an allen key in the middle? Also does it go clockwise or anti clockwise, I'm assuming clockwise??

Oh yes and in the manual the F is above the T but on mine the F is below the T, is this a problem or should I still just line up the T???

I attached an image from the manual to show what I mean.

Thanks
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