www.zxrworld.co.uk

Hi guys, Just finished changing the cam chain and valve clearances on my 1991 zxr400. just putting some shims in when i noticed that there was a crack in the end of cam cap 2. removed the cap and taken some photos. I think the cam caps are machined for each head so just wondering what you guys think i should do? i have access to a tig welder so may possibly try this. Thanks for any help, Gav.

http://s978.photobucket.com/albums/ae26 ... mcap12.jpg

I think you're right, they are machined specific with the head. Looks like you're gonna need a new head and cam caps set. Sorry

Thats a tricky one looks like it's just crack on the oil feed.................might be fixable.................


You'd need to be very good with TIG to get it right

what cargo said..

or epoxy ?

yeah think i shall take the cap into work tommorow and get the welder to give it a shot. Will hopefully work, dont fancy getting a new head

Cheers guys, Gav

You might just be lucky................before you epoxy or weld get it clean...................like very very very clean.
Any oil in there and epoxy will not stick properly and weld wont like it either.

Brake cleaner should do it nicely.

Sorry to say but I would I magine that it's cracked because it was unbolted without proper care................if you just spin the bolts out the cap will twist and break because of the pressure from the valve springs.
You need to ease each bolt in turn and allow the caps to come up together and evenly......................I'm not saying it was you but certainly that is what I would strongly suspect has happened.

As I say you might just be lucky

Lets us know how you get on

yeah cleaned the cap before i gave it to the welder but he aint in at the weekends so he is doing it on monday. Cargo- could well have been me that cracked it, did try and undo bolts evenly but one side did come up before the other. Ah well i will know for next time!! Thanks guys il keep you posted. Gav

hi guys, just thot id let you know i got the cam cap back from the welder today, Hes done a really good job and im v. pleased. Posted pics here http://s978.photobucket.com/albums/ae264/gavd_bucket/ . Thanks for the input guys gona get her back together now! thanksss, Gav

I had this problem a while back and have it again now! on a differant bike ( much worse this time round.)

The first time was caused be the oil line next to the cam chain not being seated correctly on the dowl before tightening.. I turned a bronze plug to fit in tight and had an aircraft welder go over it for me , leaving the broken peice out completely. the weld did not take to the bronze so it could be taken out and tidied up after. It cost me about 20 quid to have it welded and didnt have any problems after that.

Second time round was due to my brother being a pratt, really hope it goes as well!!

I did the cam and valves this weekend and some twat had epoxy all over the oil feed on mine. It seems to be a problem if you are not careful. The epoxy seemed to be holding so I left well enough alone.