ZZR600 E3 few niggles

[billybaggins]

Hi , haven't posted in here for a while, i've picked up a cheap, rough 1995 zzr600 with 65k miles to use for the rest of the winter. Some issues ill list if anyone can help with

1. Downshifting from a couple of gears is very stiff, almost have to hold clutch in for a few seconds until revs die down to be able to shift. I have adjusted clutch cable tonight so will get out on it in the next couple of days and see if that has any effect. Any other ideas?

2. Throttle won't spring back all the way on its own. Cable seems pretty free, my only thought is the grip is very worn and a bit out of shape so its maybe rubbing on bar end etc therefore resisting a bit, ill maybe take the grips off my vf500 to try. Any other ideas or any ideas on how to remove an awkward tight grip.... cut it off etc and lube up the new one?

3. Brakes.... the front one feels a bit notchy, eg i put it on from say 40mph and its sort of on-off-on-off but not majorly, just jerky. 1 pad is quite worn where the other 3 aren't so bad, could this affect it? Fluid level is fine, but not sure how to check if theres air etc in there.
Rear brake works when rolling bike forward though when riding it barely works, pads are good, disc is good, lever feels fairly normal although slightly hard towards the end... any ideas?

4. Front wheel is quite badly corroded, not much green paint left on it. What is the best method to smooth this before I paint it so as the paint will stick?

5. Idle was low, ive now cranked it up, but when it was low there was a rumble noise from engine area, then when I pulle din the clutch lever the rumble went, is this a sign of a clutch basket being loose of plates needing replaced?


Cheers for any help in advance, dont want to spend much money on it as shes old and for winter. Just want it safe and a bit smoother

[mentalboy]

Firstly - please note that my experience relates to the 1100 so whilst issues aren't always the same they do share some 'delightful' characteristics!

My Zed can be a complete bugger with the throttle return after a rebuild - it has always been because it is very particular about the way it is routed from the carbs and if it doesn't follow the same path EVERY time the bloody thing sticks. More often than not because it's being pinched by the tank, although it also plays stupid buggers if it doesn't go through the steering head by a specific route.

Front brake sounds as though a disc (or both) are worn and excess wear on one pad would indicate that the caliper needs servicing (probably the same disc that's knackered as it may have been cooked).

Rear brakes are generally not expected to give the same stopping performance as the front ones and often feel as though they aren't doing much - is this your first large bike, it may just be normal.

Front wheel sand back all the corrosion and peeling paint, then use a primer that's meant for aluminium.

Rumbling could be clutch basket bearing (on mine the bearing pushes out of the basket which means that when it fails at least it's a cheap job to do) but don't forget that Kawsaki's are quite agricultural when it comes to finesse and can sound very rough when idling. What happens when you increase the revs slightly? Has the rumbling gone? The clutch basket bearing is quite noticeable when it gives up - there is usually quite a disconcerting amount of noise when the bike is pottering around

Your first point could be several issues but I'd concentrate on getting the throttle cable right first, as this will also leave revs hanging when you've throttled back
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Make mine a Corona.

[wr6133]

I've got a 400k (down sleeved 600d) but a lot of stuff is the same

The tokico callipers are shite. Sounds like yours need a strip, clean and bleed. Get in the habit of blasting them with brake cleaner regularly they gum up easily. They can also be a pain in the arse to bleed properly.

Throttle as mentalboy says check the routing. I replaced my bars, ends and grips recently and didn't route exactly as per manual and had a similar issue.

Slightly rattley clutch basket is a feature don't worry unless it is really bad.

Rear brake, my k/d model uses a different (beefier looking) calliper that's pretty effective so can't help there.

[billybaggins]

Cheers guys, some things to look at. I have a vf500 too and the rear brake is a lot better on an 88 bike.
Where on the front caliper should I spray the cleaner, pull back the rubber boot and spray the piston or what?
also are the wheels aluminium? They will need a lot of sanding, I may leave them in somewhere to get that done.

[mentalboy]

[DrSnoosnoo]

I'll try and help with my limited experience with the exact model of the bike you have - slightly lower mileage though.

1. Downshifting from a couple of gears is very stiff.

When was the oil last changed? Our bikes can get a bit upset with gear changes with crappy oil and also check chain tension. When my chain gets a bit too slack, the gear shifts get clunky.

2. Throttle won't spring back all the way on its own.

Check the grip like you mention, if the bar end hasn't been off before, be careful you don't shear the bolt - use an impact driver if you can, the threadlock makes it REALLY tight.

3. Brakes.... the front one feels a bit notchy,
I assume you have the stock Tokicos? I had my bike for around 2 months before the brake lever got notchy, almost like there were 3 levels of braking. They are notorious for their demand in maintenance, keeping the pistons nice and clean. These are commonly upgraded to Nissin 4 pots - like I have done which can be neglected more without serious detriment and notchiness of the lever.

4. Front wheel is quite badly corroded

Can't help here.

5. Idle was low, ive now cranked it up, but when it was low there was a rumble noise from engine area.

Mine gives a rumble while cold, when it's warm it's better but as has been mentioned they can be tractorific

Take home - Keep on top of cleaning the brakes, and if you ever have to bleed the brakes, make sure you have a full day free.
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I'm Sam; Northern, Ginger, Lover
Did have: '95 ZZR600 '83 CG125 '97 ZZR1100 '15 Hypermotard 821 SP Do Have: '10 ZX10R

[Wonko The Sane]