www.zxrworld.co.uk

Hello, im havings problems with my headlight. It was working fine until my dad noticed they were yellow in his mirror on a bike ride, i turned them off an on agian an they corrected themselves. Not long again did they go yellow and only 1 would light up on full beam, not dimmed but bright as it should be. I handed the bike into a kawa dealers to get it sorted and they put 2 new bulbs in it saying the filaments had burnt out on 1 bulb, when i handed the bike into the dealers 1 bulb was bright on low beam and 1 was yellow, and same again only 1 would light up on full beam. The left bulb as ur sitting on the bike.

The 2 new bulbs havn't helped, they were fine for a while but now only the left bulb will go on high beam and the right bulb will die if the high beam button is pressed, but however will remain on low beam if the pass button is held. Both are fine on low beam and light up correctly. Any suggestions on this puzzle? Dont want to hand it back in to the dealers they charge 67 per hr

Thanks for any suggestions.

does the bike run fine otherwise?

Dirty contacts?

Before i handed the bike into the dealers, i had the tank off and sprayed wd40 into all the connections and checked them all. the bulbs are sitting in correctly in the headlight. I think it could be an electrical component, i think it could be blowing the filaments of the bulbs.

Any ideas?

Also the bike runs fine, starts on 3 cyclinders when cold, drinks a bit of rad fluid so dont no if the head gasket is away yet, or if the rad is leaking. Sometime a wee puddle under it afera gd run. Other than that the bike is as it should be sh*t hot!

have you checked the headlight relay?

Engine doesnt sound healthy! Sounds like the head gasket has gone indeed! What does the temp gauge look like after a good run?

Have been speaking to mechanic and he says i should put a volt meter across the battery and see what its reading when the bikes running to see if it is producing too much voltage and blowing the bulbs. i checked all the connections and all are fine. How do you chech the headlight relay?

Also i dont have a manuel and im going to change the head gasket myself, is there any instructions on how to do that?

Also how to tighten the cam chain tensioner?


And how to give the bike an oil change?

Cheers Ross

Manual is pretty basic as its aimed at people who already know what they are doing but you should still be able to do it with the manual.

Dunno how to check the headlight relay. The cam chain tensioner is automatic, so if its rattling then its needs a new tensioner. Oil can be drained from a large 17mm (i think) bolt on the left hand side of the motor.

mine rattles like a right sod, but I know the CCT is only at half distance, and valves are only slightly out. Headlight sounds like a bad connector to me.

Hi
I read your question about the cam chain tensioner and thought i'd reply.....

.... recently my bike's been making alot of noise and initially the garage thought it was 'top end', after adjusting the valve clearances the noise was still there. Willie Ralston is a race bike tuner/mechanic and knows his stuff, he works on bikes all over Scotland, works at MCS bikes in Paisly during the day and at Kypeside Country Capers (dyno tuning) in the evening.
He stripped my bike down and said that it was my cam chain tensioner that was making the noise, he tightened it and now... the bikes' running really sweet!!
It was dyno tuned, with a few odds and ends adjusted...

...anyway, cam chain tensioner can be adjusted but i can't help with anything else... trying to fit iridium bulbs to mine now

P

to "tighten" the CCT, just undo both the bolts that hold it to the engine a couple of turns to allow it to drop 2-3 mm (till it clicks once basically) then nip the bolts back up.

this just allows it to extend one more click and properly take up the slack in the camchain.

only 1 click though!! or it'll whirr like an NC30, wear out stuff and snap the camchain .. maybe .. but it'll definitely whirr anyway

Still haven't fixed the kawasaki yet. Have got a volt meter to check to see if the bike is over charging and blowing the headlight bulbs.
i dont know how to check the head light relay.

Im just about to go and get a new head gasket for the cyclinder head and install it myself, any tricky bits i will have to look out for, will be doing it without a manuel so it isn't going to be easy i think.

Few ques, how do i line the engine on its TDC stroke so i can check the valve clearances before i take off the cam shafts to put a new head gasket it, im sure i will need 1 off at least so i can take the cam chain off.

Also Zimm, i understand by retracting the Cam chain tensioner (CCT) by 2,3mm from the engine will cause it to shoot in 1 more notch so that the slack is taken up, but should it not do that any way. will be taking it right out, if im putting the new gasket in soon anyway.


Any replies would be much appreciated

Manuals are here mate

http://www.zxrworld.co.uk/zxr400/manual.html

Good luck with the rest

ross01505 wrote: Also Zimm, i understand by retracting the Cam chain tensioner (CCT) by 2,3mm from the engine will cause it to shoot in 1 more notch so that the slack is taken up, but should it not do that any way.

sometimes they stick a little, thats all. but yeh, it should thats the idea.