ZZR600 Service Manual + Advice

[chris-red]

Helping a mate sort out his bike tomorrow. It is a 93 ZZR600 I think.

I was hoping somebody had a link to a service manual I could download.


Also what would you suggest for a ZZR6 that has been sitting for about 2 years? I was going to change the fuel, plugs, oil + it needs a new battery. Give the brakes a clean and bleed.

I was also gonna clean the carbs, this is just a case of draining them, then cleaning them with a rag and some carb cleaner right?
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Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[----]

I'll start uploading the manual now...

[Ichy]

How has it been stored? In a garage or outside? Covered?

I've had loads of bikes that have sat for longer than that and, being me, I've just attached a big battery to it and cranked it over. Usually takes a fair few turns but in the majority of cases they fire up. Give it a rest after a few cranks to stop anything burning out.

Generally I'd go round with a bit of oil and grease and make sure everything is lubed. Worth checking the air filter for spiders or mice. Check the tyres for splitting and the stanchions for any rust or crud that may damage the seals. Brakes may need a bit of a overhaul to get them working, just give them a clean for starters.

Personally, cleaning carbs for me means removing them from the bike and cleaning all the jets out. Don't touch them unless you have to.

[chris-red]

It has been garaged, We tried starting it a year ago the battery is completely knackered. I figured fresh fuel and plugs while it's apart I'll check the airbox. May just hook it up to a car to crank it over and give the carbs a clean.

How easy is it to clean the carbs without knocking the settings out?
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Kickstart]

Hi

Personally I would go with Ichy.

Plugs are a pain on the ZZR (airbox off and then coils off) but probably worth doing.

The ZZR will not run without a reasonably charged battery. Had one with a flat battery and with jump leads I could get it going, but even once warm as soon as you disconnected the jump leads the engine died, even with some throttle.

Only real setting on the carbs is the balance adjustment screws (which you won't have to touch) and the idle mixture which you probably should unscrew and clean out. However with these screw them in gently and check how many turns in each is before you start (and note it down).

ZZR brakes are a pain though.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[steveh]

i have a manual somwere if your interested in a hard copy.

steve.
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Current : 06 Zx10r, 07 Wr450f SM, 74 850 norton commando, 63 bsa b40, 1962 Triton 650, 67 Triumph Tr6r, 1955 Triton 750, 1978 TY250E.

[chris-red]

THanks for the offer but I have a electronic copy now, I'll print out the usefull parts.

Striped it yesturday couldn't find a good battery so it wouldn't turn over. Discovered it needs a new..


Air filter,
Battery,
Throttle cables,

At least before it runs.

The panels are all in good nick a few marks but not one crack or broken lug. Most of the bolts seem to be mix and match with it.

Keith was right about the brakes. WTF? they where binding so pumped the pistons out to clean them only to discover that they are spot less but now will not go back into the caliper even with the bleed nipple cracked. I had a quick look on the forums and they say CBR nissins more or less bolt on so I may do that. Also the pistons seem to have rubber bungs in the piston holes. What is this for? The only thing I could think of was to stop the pads rattling.

Any advice on the brakes Keith?

Would there be any ill effects if I was to hook a car battery up to it to turn it over?

Oh yeah could seem to find the plug gap in the manual anyone know it?

Thanks

Chris
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Kickstart]

Hi

If you can get someone to make up the spacers then use the alternative calipers would be my main bit of advice.

The calipers are pigs. The corrode badly and are a pig to bleed. Also not sure they are particularly rigid. What you can try is to pump the pistons out, pop the seals out and clean the calipers and pistons thoroughly. Especially corrosion in the grooves the seals sit in. Reassemble carefully and refit.

Think the stuffers in the pistons are there to try and insulate the calipers from the heat generated in the pads. Think the bungs are used in early calipers while later ones have a stuffer moulded into them.

I would connect it to a car battery to crank it over. Just be careful that the connections are decent and that nothing shorts out. And avoid sitting on the starter motor for too long.

Plug gap is 0.7~0.8mm (along with about 95% of bikes it seems).

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[chris-red]

Thanks Keith accord to some posts on the ZZR forum you only need washer on each bolt to space on the calipers I'll ask.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Kickstart]

Hi

The mounting bolts are smaller on the CBR calipers. So what you need is a tube spacer to take up the gap between the bolts and the mounting holes in the forks. Might need something to offset the caliper as well a touch but not sure.

While some people do just put the caliper in place using the smaller bolts and tighten them up I am dubious about leaving the calipers not secured properly.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Ol]

Sorry for the Bump...

Does anyone have a link to where i can download a 2001 ZZR600E9 service manual ??

Cheers,
Ol.

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