Engine & Transmission

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new fileset

Last post by masterofinsanity « Tue Jun 11, 2019 7:47 pm
Posted in GENERAL ANNOUNCEMENTS, RULES AND UPDATES.

by masterofinsanity » Tue Jun 11, 2019 7:47 pm » in GENERAL ANNOUNCEMENTS, RULES AND UPDATES.

Hi, i have upgraded to the latest fileset please report any missing links, images or errors here.

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Last post by masterofinsanity
Tue Jun 11, 2019 7:47 pm

Topics

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Last post

Correct Cam Timing + Chain Fitting

Last post by Mxdeano « Mon Oct 01, 2018 9:30 pm
Replies: 21
by Randle » Tue Jul 03, 2012 5:42 pm
1

2
I just fitted a new cam chain, so I thought I would post a few pics to help people do the same task.
The part of the work I am focusing on is fitting...
21 Replies

9568 Views

Last post by Mxdeano
Mon Oct 01, 2018 9:30 pm
zxrworld shim collection

Last post by RSVR « Mon Feb 19, 2018 11:34 am
Replies: 36
by masterofinsanity » Fri Dec 18, 2009 11:22 pm
1

2

3
I will keep a record here of the shims we have collected.If you have any spare then please send them to me, i will keep a stash and post out to...
36 Replies

7703 Views

Last post by RSVR
Mon Feb 19, 2018 11:34 am
new zxr 400 pistons at last

Last post by GavPJ « Thu Aug 08, 2013 12:35 pm
Replies: 7
by toecutter » Wed Feb 09, 2011 7:45 pm

Hi folks as mike has said in the racing section i have done the pistons at last what a bloody trauma its been
if some one can tell me how to post...

7 Replies

3639 Views

Last post by GavPJ
Thu Aug 08, 2013 12:35 pm
Cylinder head size

Last post by neston « Tue May 07, 2019 5:29 pm
Replies: 5
by neston » Sun May 05, 2019 5:05 pm

Hello,
I'm having trouble finding out the standard size of a ZXR400 cylinder head , I need to know the height of the head in order to find out if a...

5 Replies

658 Views

Last post by neston
Tue May 07, 2019 5:29 pm
Engine identification

Last post by ickle pob « Fri Apr 05, 2019 12:49 pm

by ickle pob » Fri Apr 05, 2019 12:49 pm

Anyone know where I can confirm engine identification off an engine number alone ?

Waiting for Kawasaki UK technical to get back to me but someone...

0 Replies

190 Views

Last post by ickle pob
Fri Apr 05, 2019 12:49 pm
Chipped valve guide

Last post by ChowderV4 « Tue Mar 05, 2019 10:13 pm
Replies: 2
by ChowderV4 » Mon Mar 04, 2019 10:17 pm

Stripping a head on a motor I'm. Working on and have come across a chipped inlet valve guide.
Doesn't look to be cracked and I have no idea how long...

2 Replies

382 Views

Last post by ChowderV4
Tue Mar 05, 2019 10:13 pm
Cam timing chain install

Last post by banner001 « Mon Feb 25, 2019 9:16 pm
Replies: 1
by greenville » Mon Feb 25, 2019 6:40 pm

Hi

Anyone that can perhaps with some instructions or a link to a how to video or manual on how to replace the cam timing chain on a 1989 Yamaha...

1 Replies

322 Views

Last post by banner001
Mon Feb 25, 2019 9:16 pm
Low Compression

Last post by Jake99 « Wed Jan 30, 2019 12:37 pm
Replies: 15
by Miles » Tue Sep 08, 2009 3:03 pm
1

2
Ran a compression test on the bike and found it to be out of range on two cylinders and just within on the other two.

So I thought that maybe some...
15 Replies

2158 Views

Last post by Jake99
Wed Jan 30, 2019 12:37 pm
Valve Guide Removal

Last post by ChowderV4 « Fri Jan 25, 2019 12:37 am
Replies: 4
by Wagman2000 » Sun Jan 20, 2019 11:35 am

Due to slightly bent Valves I’ve damaged the valve guide removing it (Part of a bigger problem. I have a new top end coming but I thought I could...

4 Replies

433 Views

Last post by ChowderV4
Fri Jan 25, 2019 12:37 am
Help

Last post by Parso « Mon Oct 08, 2018 11:45 am
Replies: 4
by Parso » Sun Oct 07, 2018 5:14 pm

Hello guys I have a problem with my cylinder barrels can someone tell me how to remove the cylinder liner from cylinder block ?

4 Replies

1329 Views

Last post by Parso
Mon Oct 08, 2018 11:45 am
Help with splitted case

Last post by banner001 « Tue Oct 02, 2018 1:45 pm
Replies: 4
by Parso » Tue Oct 02, 2018 7:24 am

Hello I have a problem with my zxr 400 L5 case it seems that I can' fit the case back in original form I mean that I splitted the case yesterday for...

4 Replies

430 Views

Last post by banner001
Tue Oct 02, 2018 1:45 pm
Changing from 1st to 2nd gear doesn't really work

Last post by banner001 « Tue Oct 02, 2018 7:03 am
Replies: 8
by Catalin24 » Sat Sep 29, 2018 4:00 pm

Hello friends! please help me because this drives me crazy.
The problem is as follow:
Trying to shift from 1st gear to 2nd gear at low rpm's...

8 Replies

701 Views

Last post by banner001
Tue Oct 02, 2018 7:03 am
Cams

Last post by Mxdeano « Sun Sep 30, 2018 8:29 pm

by Mxdeano » Sun Sep 30, 2018 8:29 pm

Hi all , when your cams are aligned to the cylinder head with the mark on the sprocket ie 3pm-9pm should the notches on the cams on left hand side of...

0 Replies

268 Views

Last post by Mxdeano
Sun Sep 30, 2018 8:29 pm
Running temps without oil cooler

Last post by Si81 « Sun Sep 30, 2018 6:53 pm

by Si81 » Sun Sep 30, 2018 6:53 pm

So my L9 had an oil leak on a pretty badly corroded oil cooler. So, after doing some research on here decided to remove it altogether and use the...

0 Replies

244 Views

Last post by Si81
Sun Sep 30, 2018 6:53 pm
Shim Issue

Last post by Mxdeano « Sat Sep 29, 2018 8:15 pm
Replies: 11
by fergy150 » Fri Aug 05, 2016 12:25 pm

Bought a new engine to use while I'm giving mine a full rebuild, told it was in perfect working order, only done 16,000 miles took it apart and found...

11 Replies

1347 Views

Last post by Mxdeano
Sat Sep 29, 2018 8:15 pm
Throttle snap back

Last post by Miles « Sun Sep 23, 2018 11:24 pm
Replies: 2
by Si81 » Sat Sep 22, 2018 9:14 pm

So my zxr is my first ever road bike. I've only ever ridden/raced motocross bikes. Generally i'm used to a very very light snappy throttle action,...

2 Replies

230 Views

Last post by Miles
Sun Sep 23, 2018 11:24 pm
Oil/water/condensation/HG question (sorry in advance)

Last post by banner001 « Thu Sep 20, 2018 11:08 pm
Replies: 3
by Si81 » Thu Sep 20, 2018 1:30 pm

Hi guys,

I know that this question comes up a lot but i'm completely new to zxr's and have just picked up my first - a 2000 model.

It all looks...

3 Replies

352 Views

Last post by banner001
Thu Sep 20, 2018 11:08 pm
Kent cams versus sp cams???

Last post by Zxr400paul « Wed Sep 12, 2018 8:56 pm

by Zxr400paul » Wed Sep 12, 2018 8:56 pm

Does anyone have any direct comparison between sp cams and Kent reprofiled cams, the motor has +1mm JE pistons and sp gear box with ram air and cv...

0 Replies

239 Views

Last post by Zxr400paul
Wed Sep 12, 2018 8:56 pm
Zxr 400 l6 colour code?

Last post by Smokingviper1 « Wed Jun 20, 2018 2:13 pm
Replies: 5
by Smokingviper1 » Mon May 07, 2018 1:24 am

Any one know colour code for the lime green on L6 or know where i can get it? Like can paint shops accurately see what colour it is?

Sent from my...

5 Replies

574 Views

Last post by Smokingviper1
Wed Jun 20, 2018 2:13 pm
Something doesn't seem quite right..

Last post by banner001 « Tue May 22, 2018 6:48 pm
Replies: 6
by JordBanny » Mon May 21, 2018 7:44 pm

Took my bike out Sunday after being stored for some 2 years! After a service of course!
And after 20 or so miles it developed a rattle almost...

6 Replies

506 Views

Last post by banner001
Tue May 22, 2018 6:48 pm
Rocker Arm Damage!!

Last post by DanL397 « Sat May 12, 2018 5:22 pm
Replies: 5
by DanL397 » Sat May 12, 2018 1:30 pm

Anyone had rocker arm damage like this? I`m gutted, had all my nw shims delivered today and spotted this just as i was about to start. :smt011...

5 Replies

415 Views

Last post by DanL397
Sat May 12, 2018 5:22 pm
Engine runs "backfirey". Backfires at high rpm. Hard to start when hot

Last post by banner001 « Tue May 08, 2018 12:13 am
Replies: 7
by Catalin24 » Fri May 04, 2018 12:02 pm

Hello I need help with my ZXR 400 L5, it has quite a list of problems..

PLEASE FORGIVE ME FOR THE HUGE POST BUT I WANT TO EXPLAIN AS BETTER AS I...

7 Replies

510 Views

Last post by banner001
Tue May 08, 2018 12:13 am
Engine sounds like turbo charged...whining

Last post by Smokingviper1 « Thu Apr 26, 2018 4:43 am

by Smokingviper1 » Thu Apr 26, 2018 4:43 am

Soooo done an oil chain, new filter, had to replace sump with new one, after a week of doing that put back together there is now a distinctive whine...

0 Replies

250 Views

Last post by Smokingviper1
Thu Apr 26, 2018 4:43 am
conrod latest model

Last post by hub74 « Fri Feb 02, 2018 7:23 am
Replies: 2
by hub74 » Tue Dec 05, 2017 2:38 pm

Hello
I look for one (or more) conrod ref 1208
This conrod was on the latest models.
sorry for my English !
Thank
HUBERT France

2 Replies

489 Views

Last post by hub74
Fri Feb 02, 2018 7:23 am
Piston ring end gaps

Last post by Zxr400paul « Tue Jan 23, 2018 6:56 pm

by Zxr400paul » Tue Jan 23, 2018 6:56 pm

Hi people, I’m looking for advice on piston ring end gaps. I’m refreshing my race engine and the manual spec for end gaps on the ring seem large...

0 Replies

286 Views

Last post by Zxr400paul
Tue Jan 23, 2018 6:56 pm
Cam Chain Tensioner?

Last post by Smokingviper1 « Mon Jan 15, 2018 7:37 pm
Replies: 37
by Madderz » Sat May 03, 2014 12:30 pm
1

2

3
Hey guys,

New to the forum so urmmm HI!

Picked up my 92 ZXR400 the other day. Love it to bits. Arrived at work today and a couple of the guys said...
37 Replies

4833 Views

Last post by Smokingviper1
Mon Jan 15, 2018 7:37 pm
ZXR 400 Engine?

Last post by TheBadMechanic « Sun Dec 17, 2017 12:43 pm

by TheBadMechanic » Sun Dec 17, 2017 12:43 pm

Not sure if this is the right place but my amazing ZXR 400 that's had some internal work done by the previous owner is now clicking and ticking...

0 Replies

337 Views

Last post by TheBadMechanic
Sun Dec 17, 2017 12:43 pm
Sell / buy 3 Wossner HC piston +0.5

Last post by hub74 « Tue Dec 05, 2017 3:02 pm

by hub74 » Tue Dec 05, 2017 3:02 pm

I sell 3 Wossner HC piston size 57,50 mm (only 3)
I used them only 3 weekend !
If not, I buy one piston.
regards
HUBERT France

I can send pictures...

0 Replies

327 Views

Last post by hub74
Tue Dec 05, 2017 3:02 pm
SP gearbox identification

Last post by ChowderV4 « Mon Nov 27, 2017 8:27 pm
Replies: 6
by Miles » Fri Dec 25, 2015 3:04 pm

Happy Xmas everyone,

Just a quick one. While waiting for Xmas lunch to appear I've been sorting out gearboxes.

Thing is I thought the difference...

6 Replies

1407 Views

Last post by ChowderV4
Mon Nov 27, 2017 8:27 pm
Advice replacement engine?!

Last post by NeiiseZXR « Tue Sep 26, 2017 3:03 pm
Replies: 19
by NeiiseZXR » Mon Apr 04, 2016 2:45 pm
1

2
My zxr400 failed compression in cylinder 1.. Possible that a valve has dropped...damaging piston head, head cylinder etc..

I've come across this...
19 Replies

2559 Views

Last post by NeiiseZXR
Tue Sep 26, 2017 3:03 pm
Can guard

Last post by Probablyhungry « Wed Jun 28, 2017 8:26 pm

by Probablyhungry » Wed Jun 28, 2017 8:26 pm

Will the cam chain guard of the h model fit the l.

0 Replies

494 Views

Last post by Probablyhungry
Wed Jun 28, 2017 8:26 pm
Sp cams

Last post by banner001 « Wed Jun 28, 2017 9:26 am
Replies: 1
by Miles » Wed Jun 28, 2017 12:41 am

Quick one. Does fitting adjustable cams require a different ignition disc on the crank to be fitted?

I've had the cams dailled in professionally so...

1 Replies

506 Views

Last post by banner001
Wed Jun 28, 2017 9:26 am
Very bad (loud) engine rattle

Last post by Moonfire « Fri Jun 23, 2017 7:12 pm
Replies: 8
by Moonfire » Wed Mar 18, 2015 2:08 pm

Hi, I've got a 1993 L3 which has just developed a very loud engine rattle. I realise that without seeing the bike and hearing it it's pretty much...

8 Replies

1984 Views

Last post by Moonfire
Fri Jun 23, 2017 7:12 pm
Steam Train Noise

Last post by hectormedlicott « Sun May 28, 2017 6:55 pm
Replies: 4
by hectormedlicott » Wed Apr 27, 2016 3:50 pm

Hi, when im riding my zxr 400 it sounds a bit like a steam train going shh shhh shhh shhh! its does it in all gears at all speeds however the faster...

4 Replies

1152 Views

Last post by hectormedlicott
Sun May 28, 2017 6:55 pm
Engine noise at low rpm

Last post by banner001 « Sat May 27, 2017 5:57 pm
Replies: 3
by GeorgeMoroz » Wed Apr 12, 2017 11:02 pm

So my engine gave out and i got an ex race engine, the guy hadnt touched it internally just oil and filter changes, i drop it in start it up and i've...

3 Replies

729 Views

Last post by banner001
Sat May 27, 2017 5:57 pm
Is it time for a new timing chain?

Last post by banner001 « Tue May 09, 2017 2:15 pm
Replies: 8
by nettns » Sat Jul 30, 2016 6:22 pm

I've been getting a rattle at 3500rpm. Its not present below or above that speed, it only becomes noticeable at 3500rpm. Today I pulled off the cover...

8 Replies

1436 Views

Last post by banner001
Tue May 09, 2017 2:15 pm
Cam caps - removal procedure

Last post by Moonfire « Fri May 05, 2017 6:21 pm
Replies: 2
by Moonfire » Thu May 04, 2017 7:39 pm

Hi,

I'm just about to remove the cam caps from an L3 in order to fit a new timing chain and have read about the importance of taking the torque of...

2 Replies

714 Views

Last post by Moonfire
Fri May 05, 2017 6:21 pm
Rattle at 5500rpm

Last post by bendog66 « Wed Feb 22, 2017 10:39 pm
Replies: 2
by D0n H » Tue Sep 13, 2016 8:42 am

Hi Guys

Just a quick one i seem to be getting a rattle at about 5500rpm it will only come and go thew the stage of accelerating im not sure what to...

2 Replies

852 Views

Last post by bendog66
Wed Feb 22, 2017 10:39 pm
Sludge in engine

Last post by watsonm359 « Wed Feb 01, 2017 8:08 pm
Replies: 7
by Dutch_ZXR » Thu Jan 26, 2017 9:16 pm

Hi,

I recently (two weeks ago) bought myself a ZXR400 and it rode perfectly for about 600km.

Since today I'm dealing with 2 issues:

First issue:...

7 Replies

1055 Views

Last post by watsonm359
Wed Feb 01, 2017 8:08 pm
Standard squish - please help

Last post by Rubencio « Tue Jan 31, 2017 4:44 pm
Replies: 4
by Rubencio » Mon Jan 30, 2017 10:15 pm

Hi Lads, I would need to know the piston to head clearance (squish) on a standard L8 engine.
Thanks in advance
Rubencio

4 Replies

818 Views

Last post by Rubencio
Tue Jan 31, 2017 4:44 pm
Hight performance pistons query.

Last post by Ewetea « Sun Dec 04, 2016 4:42 pm
Replies: 3
by Rubencio » Tue Nov 29, 2016 12:11 pm

Hi Guys,
I have got a head for an L9, I am sending it for porting and polishing.
Having the head down I could do sometimes with the pistons.
I am...

3 Replies

871 Views

Last post by Ewetea
Sun Dec 04, 2016 4:42 pm
Engine swap on ZXR400 1991

Last post by fergy150 « Thu Oct 13, 2016 1:58 pm
Replies: 1
by brutus » Mon Oct 03, 2016 8:52 am

Hi!!!
I'm an happy owner of a glorious ZXR400 1991, but the age is not only a number, I like to build a custom bike based on my ZXR400 to use it only...

1 Replies

816 Views

Last post by fergy150
Thu Oct 13, 2016 1:58 pm
Sp cams and big bore

Last post by Miles « Sat Aug 27, 2016 9:46 pm
Replies: 1
by daktari » Sat Aug 27, 2016 4:38 pm

Hey.

Where can i find a set of sp cams and gearbox .
What's the best big bore kit whitin race regulations.
For racing use.
Thanks

1 Replies

747 Views

Last post by Miles
Sat Aug 27, 2016 9:46 pm
Zxr 400 L 1991 and engine from H model 1989

Last post by banner001 « Fri Aug 19, 2016 10:32 am
Replies: 7
by zyniu » Thu Aug 18, 2016 9:22 am

Hi. I have a Zxr400 L model with engine gone and i bought the engine from H model and im wondering what parts do i have to swap as well as the...

7 Replies

1174 Views

Last post by banner001
Fri Aug 19, 2016 10:32 am
Odd noise

Last post by nettns « Thu Jul 28, 2016 8:37 am
Replies: 4
by belroy » Sun Sep 25, 2011 5:02 pm

Recently just did all my valve clearances, changed the cam chain and checked the guides in one fell swoop, now between 3.5k and 4k revs there is a...

4 Replies

1105 Views

Last post by nettns
Thu Jul 28, 2016 8:37 am
No compression on all cylinders

Last post by Siuras « Sat Jul 23, 2016 11:23 pm
Replies: 2
by Siuras » Sat Jul 23, 2016 9:51 pm

Hi, I did an engine rebuild by myself. I have changed almost everything.. Just valves left the same, and I have no other idea what check yet.
First...

2 Replies

886 Views

Last post by Siuras
Sat Jul 23, 2016 11:23 pm
Oil and Water Ways/Channels

Last post by banner001 « Thu Jul 14, 2016 11:00 am
Replies: 1
by worthidlj » Wed Jul 13, 2016 12:50 pm

Hey guys, was looking at the underneath of the cylinder head and wondered which channels were for water ways and which are oil?

As reference see...

1 Replies

696 Views

Last post by banner001
Thu Jul 14, 2016 11:00 am
Engine Parts Advice

Last post by Tricey27 « Sun Jul 10, 2016 10:17 am
Replies: 3
by Tricey27 » Sat Jul 09, 2016 10:27 pm

Hi,

In process of working on my new '89 ZXR 400 project and wanting to do the timing chain and head gasket. The bike has done 19,000 miles but want...

3 Replies

841 Views

Last post by Tricey27
Sun Jul 10, 2016 10:17 am
Shim questions zxr400

Last post by jamesgoodfella « Fri Jun 03, 2016 8:02 am
Replies: 1
by fstarocka » Wed May 04, 2016 6:38 am

Hi guys, new here and first post.. Bought a 90 h model last month.. Just put in new rings and got her running last night!!

Anyway, did some...

1 Replies

695 Views

Last post by jamesgoodfella
Fri Jun 03, 2016 8:02 am
Cam cap bolts

Last post by jamesgoodfella « Wed Jun 01, 2016 9:07 pm
Replies: 9
by Johnhas » Mon May 30, 2016 11:26 pm

Does anyone happen to know what thread an pitch they are? I'm building up an engine I got in bits and there missing, hoping to buy the bolts from a...

9 Replies

1088 Views

Last post by jamesgoodfella
Wed Jun 01, 2016 9:07 pm

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