www.zxrworld.co.uk

Right, over teh next couple of nights im hoping to get teh engine out and onto my bench.

Plan from there is to strip it down and replace the following -

Gaskets (set is £40 so figure might as well do them all as engine will be apart)

Cam chain

Chain tensoner (this will be old style as is H model) - is there a test to see if tensioner needs replacing too ? its got 40K on it so figured best to replace)

Am going to do clearances / new shims too

Is there anything I am missing that should get done at same time - will head need to be skimmed ?

(am doing HG as the bike was having some overheating issues - so figured as it will be out of bike to get it resprayed now is as good a time as any)


Finally what sequence am i best off doing this in ??? - do i strip it down and do all gaskets first ?

Im pretty novice with engines, but have time on my side - and am in no rush to get it back on teh road / want to learn

Cheers

Ian

one other thing - lifting teh engine ! is it a 2 man lift ??? or more !

i've just done the rings, gaskets and cam chain on my L model and did it on my own with the engine in the frame. its the first 4 stroke i've stripped down after years of 2 strokes, i just kept a list of where things came from,etc and found it quite straight forwards.
if you want to get the motor out on your own without damaging it i reckon the best way would be to either lay the bike on its side or lower it out using a trolley jack or something to take its weight
as for order i'd get it stripped down then get your gaskets sorted and sealed and the head torqued back up then look at doing the bits at the top of the engine.

have fun

thanks

engines nearly full disconnected /drained, so will try and drop it out this evening so can get cracking this weekend - after a trip to cradleys

so I want to be replacing:

top and bottom gasket
cam chain / maybe tensioner
piston rings

reconnect / fill up with oil - jobs a good un

anything else that should be done / worth consdierng whilst its out ???

I wouldn't do the base gasket and rings if their ok tbh, I only did mine because I bought the bike with a damaged motor. Suppose it depends how far you want to take the rebuild though... Personally I'd just build head gasket upwards and do anything to the valves, clearances, etc that needs doing along the way if the pistons and barrels seem to be in good order:)

BUGGER !!!

got the the HG eventually and it looks fine !!!! but might as well replace now that I've fetched it all apart - had a nightmare getting teh camshafts off as the allen bolt on the cam chain cover at teh top had seized in place, had to try everything to get it off, had to drill it out in the end !

anywho - my issue now is removing teh old cam chain, guides / tensioner look fine, but as its apart, i want to do the cam chain too now - question is how do i get the bugger out ???

even with the slack on the chain i cant seem to get it out. Have heard of people dremeling the case, but I know zimm says it can be done without doing this - do i need a chain link removal tool like you would use on a bike ???

Cargo dremmaled my engine last night, took under a minute to do , shaved under a mm of material away from the engine, pulled the old cam-chain out and new one in

I've also heard you can juggle them out but this is the easiest way to do it.

(P.s Cargo if you see this again massive thanks!)

what you mean is he dremmeled away the little bit of casing at the bottom just underneath the bottom cam chain sprocket.

yeah i get what he means / saw it in the other post about removing the cam chain - but have seen zimm say that there is no need to do this - but looks like i will have to go down this route, dont have a dremel though !!!

got it out without having to dremmel thr case, just turned the 6mm allen a bit and wiggled the chain and it came out relativley easily - nice one zimm !

got hg £16, new cam chain tensioner £25, cam chain £26 and 1 x bolt n washer (£5 !!!! the one from the top cam chain guide by the rocker covers- as I had to drill one of these out due to it being seized)

So going to pop all that on and do the shims / carb balancing