zxr project

andym · World Chat Champion Joined: 16 Nov 2010 Karma :

I guess I should mention this thread as it's the same bike:
https://www.bikechatforums.com/viewtopic.php?t=253760

Unfortunately when I got my grubby mits on the bike it was a bit dead in the engine department (well it would run, but the bottom end was knocking).

There is a lot of good points about the bike, but also some bad points too, hopefully a lot of the mechanical things (other than the engine), has been sorted, and to be honest I haven't really done much so far, partly because my workshop keeps getting flooded when it rains/snows:
https://img.photobucket.com/albums/v320/andy36586/Workshop_zps3cfa0851.jpg

I don't have many photos of the condition the bike was in when I got it, and this is probably the best one:
https://img.photobucket.com/albums/v320/andy36586/ZXr2_zpsaead5a32.jpg

After a few hours work it was all back together (just I'd messed up the timing and couldn't get it to start):
https://img.photobucket.com/albums/v320/andy36586/Rebuilt1_zpsd4d7fbfd.jpg

Some of the things I've done so far, stripped and rebuilt the carbs (found 1 jet in the bowl and 1 missing, but replaced them with parts from the spare carb), need to check the balance when everything is back together.

Stripped the top of the engine (and part of the bottom).

Started stripping the panels as there are bubbles on the rear panels which go down to the original paintwork (while sanding I've noticed it's been repainted 3 times. from original to blue twice then back to green), but the stripping is slow going, Also started stripping 1 of the petrol tanks, and finding where all the dents have been filled and checking that any bubbles are just surface rust (so far they have been), inside the tank has a bit of rust so I'll need to do a spot of electrolysis (been looking for an excuse to try that again), then treat the inside with the remains of a bottle of kreem.

One of the major problems with this bike is the frame just looks a little tired, and could be doing with getting stripped back and either powder coated or painted (I'll see how the funds go though)

I know there isn't a lot of pictures yet, but I'll get round to adding more.... soon

Pol Anorl · Banned Joined: 13 Apr 2010 Karma :

Hope you get on well with it, v5 has been sent by me this time!

I did start on the frame, the right is fairly easy to polish i just ran out of time, the left was sprayed like 4 layers of paint which was a pain.

let me know if you find what the rattle was.
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UnspeedySam · World Chat Champion Joined: 25 Nov 2009 Karma :

I'll be watching this with interest. So do you mean you've already stripped the bottom end, or that you still need to do that? Your post confuses me Sad

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Riding: BMW R1150RT `02 bought mildly crashed
Fixing: Also the BMW as I get less broken bits
Gone: ZZR600 '00, TRX850 '97, RXS100 '93, JS125-6B '07, BMW R1100RS '93, Kawasaki ZX-6R-J2 '01, Honda Bros NT400 NC25 '88

Hetzer · Super Spammer Joined: 19 Feb 2007 Karma :

So did you find out what the knocking was? Confused

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Supermoto_Fan · World Chat Champion Joined: 10 Jun 2012 Karma :

I do like these.. The fairings and the twin round lights do it i think. Thumbs Up

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andym · World Chat Champion Joined: 16 Nov 2010 Karma :

I did actually put a post in the workshop about the knocking, so didn't want to put all the same pictures in both threads.

Anyway, here's the video I posted which hopefully makes it obvious where the problem is:

https://www.youtube.com/watch?v=TlVkaxwTMWk

For people that don't want to watch a shakey video, I took the head off the engine and found a couple of pistons have been slapped by the valves and have dented slightly (not sure if I need to replace them), piston 1-3 have no vertical movement, but 4 does and makes quite a lot of noise doing so. So I could have stripped the engine from the bottom and saved myself the cost of gaskets possibly.

I had removed the sump last week and found there was grey sludge and metal flakes in there, but hopefully it won't be too expensive to fix.

Also it was recommended that I use tubs to keep the parts of the engine seperate, that didn't quite work as I wanted it to, the little tubs are empty (I think there is 1 bolt between 8 tubs), and the rest of the engine is either sitting on the drive in bags or in a box in my bedroom, I'll post a picture later.

TUG · World Chat Champion Joined: 12 May 2007 Karma :

I would replace the engine or find a donor with a fucked gearbox and donor the box from the fucked one etc. But thats my inclination as I would imagine the valves being bent, poor running due to that and the metal in the engine damaging a few other parts. The fact there is metal in the oil is a worrying sign indeed.
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andym · World Chat Champion Joined: 16 Nov 2010 Karma :

andym · World Chat Champion Joined: 16 Nov 2010 Karma :