Head Gasket help!!!
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- Posts: 10
- Joined: Tue Jan 14, 2014 11:20 am
- My Bike: zxr 400
Head Gasket help!!!
i just done my head gasket on my zxr400L
after putting it back together i am absolutely sure i got the timing right!
BUT on start up it sounded FINE UNTIL!!! the fuel came through and it started fireing then i started getting a crunching noise, it sounded a bit like a ducatti..... can someone please tell me what is going on.. i havnt started it since incasse i damage it
after putting it back together i am absolutely sure i got the timing right!
BUT on start up it sounded FINE UNTIL!!! the fuel came through and it started fireing then i started getting a crunching noise, it sounded a bit like a ducatti..... can someone please tell me what is going on.. i havnt started it since incasse i damage it
- banner001
- Track day God
- Posts: 2589
- Joined: Sat Sep 24, 2011 3:27 pm
- My Bike: ZXR400 L4
- Location: Nuneaton
Re: Head Gasket help!!!
gonna need a TON more information before we can help you, there is too much that can be wrong to help you at the point.
you said you did the timing, all you need to do is make sure that when the T mark lines up with the crank case joining mark, that your 2 cam lobes on #4 cylinder are pointing away from each other, the timing marks on the cams should be pointing away from each other in line with the top of the engine, and there should be 31 pins from timing mark to timing mark (including the pins touching the timing mark)...thats all there is to it.
check all your rockers/shims cam covers etc are there and bolted down.
make sure that you torqued the head in the correct sequence and with the correct values.
make sure your chain guides are in place and the chain is not slack/check the tensioner.
check all your spark plugs are seated...check everything basically and report back.
you said you did the timing, all you need to do is make sure that when the T mark lines up with the crank case joining mark, that your 2 cam lobes on #4 cylinder are pointing away from each other, the timing marks on the cams should be pointing away from each other in line with the top of the engine, and there should be 31 pins from timing mark to timing mark (including the pins touching the timing mark)...thats all there is to it.
check all your rockers/shims cam covers etc are there and bolted down.
make sure that you torqued the head in the correct sequence and with the correct values.
make sure your chain guides are in place and the chain is not slack/check the tensioner.
check all your spark plugs are seated...check everything basically and report back.
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said![:smt003](./images/smilies/003.gif)
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said
![:smt003](./images/smilies/003.gif)
- Mori Man
- Blingmeister
- Posts: 1976
- Joined: Thu May 10, 2007 3:30 pm
- My Bike: ZXR400J2
- Location: JAPAN
Re: Head Gasket help!!!
Did you reset your tensioner properly ?
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
Living life on the edge, SuPposedly
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- Posts: 10
- Joined: Tue Jan 14, 2014 11:20 am
- My Bike: zxr 400
Re: Head Gasket help!!!
i have checked the timing again and it is still spot on...
when taking the bike back apart one of the ignition leads fell off of the plug and the cable is knackered so that could be a
problem
when you say check the rockers and shims what am i checking for??
thanks you are very helpfull
when taking the bike back apart one of the ignition leads fell off of the plug and the cable is knackered so that could be a
problem
when you say check the rockers and shims what am i checking for??
thanks you are very helpfull
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- Posts: 10
- Joined: Tue Jan 14, 2014 11:20 am
- My Bike: zxr 400
Re: Head Gasket help!!!
i have checked the timing again and it is still spot on...
when taking the bike back apart one of the ignition leads fell off of the plug and the cable is knackered so that could be a
problem
when you say check the rockers and shims what am i checking for??
thanks you are very helpfull
when taking the bike back apart one of the ignition leads fell off of the plug and the cable is knackered so that could be a
problem
when you say check the rockers and shims what am i checking for??
thanks you are very helpfull
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- Posts: 10
- Joined: Tue Jan 14, 2014 11:20 am
- My Bike: zxr 400
Re: Head Gasket help!!!
i just put the tension back in and screwed it up how are you supost to do it?
- Mori Man
- Blingmeister
- Posts: 1976
- Joined: Thu May 10, 2007 3:30 pm
- My Bike: ZXR400J2
- Location: JAPAN
Re: Head Gasket help!!!
Err, think we have a winner !!george1992 wrote:i just put the tension back in and screwed it up how are you supost to do it?
I actually need to go read again as I have both types - anyhoo , all in the workshop manual available to view on
http://www.zxrworld.co.uk
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
Living life on the edge, SuPposedly
- Mori Man
- Blingmeister
- Posts: 1976
- Joined: Thu May 10, 2007 3:30 pm
- My Bike: ZXR400J2
- Location: JAPAN
Re: Head Gasket help!!!
Actually the supplement doesn't cover the new type tensioner
I will need to actually look at one again but something like:
There is a lock bolt on side of body , while the unit is removed loosen this bolt and push the plunger into body then tighten this bolt to lock.
Fit body back onto engine , loosen the bolt again to allow the plunger to tension the chain , tighten the bolt. Manually spin the engine two or three full revolutions and you should hear taking up the slack.
If you've fitted it with the plunger fully extended you have exerted way too much pressure on the chain and guides - you may have damaged them , you may have got lucky though.
Read the chapter in the H manual on the tensioner and adjust for the new body.
![:smt017](./images/smilies/017.gif)
I will need to actually look at one again but something like:
There is a lock bolt on side of body , while the unit is removed loosen this bolt and push the plunger into body then tighten this bolt to lock.
Fit body back onto engine , loosen the bolt again to allow the plunger to tension the chain , tighten the bolt. Manually spin the engine two or three full revolutions and you should hear taking up the slack.
If you've fitted it with the plunger fully extended you have exerted way too much pressure on the chain and guides - you may have damaged them , you may have got lucky though.
Read the chapter in the H manual on the tensioner and adjust for the new body.
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
Living life on the edge, SuPposedly
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- Posts: 10
- Joined: Tue Jan 14, 2014 11:20 am
- My Bike: zxr 400
Re: Head Gasket help!!!
when utting it back together i printed off all the torqe settings and when putting the cam covers back on snapped a bolt in the head because it was to tight!!!!!!!!!!!!! now bloody what iv had nothing but trouble doing this stupid thing
- Smousley1995
- Posts: 140
- Joined: Wed Apr 03, 2013 9:22 am
- My Bike: Zxr 400 L 1993
- Location: Swansea
Re: Head Gasket help!!!
Story of my lifegeorge1992 wrote:now bloody what iv had nothing but trouble doing this stupid thing
![pmsl :pmsl](./images/smilies/Laie_67.gif)
Do you mean the half bearings for the cams or the actual cam cover?
Why take life so seriously, your not going to come out alive!
- Mori Man
- Blingmeister
- Posts: 1976
- Joined: Thu May 10, 2007 3:30 pm
- My Bike: ZXR400J2
- Location: JAPAN
Re: Head Gasket help!!!
Had you ever worked on an engine before this , if so what type ?
A bolt should never sheer if tightened up with a torque wrench at the right setting - something else went Pete Tong there
When I service an engine with a head gasket swap I'll do a photo guide - it's not complicated![geek geek](./images/smilies/icon_e_geek.gif)
A bolt should never sheer if tightened up with a torque wrench at the right setting - something else went Pete Tong there
![confuddled confuddled](./images/smilies/icon_e_confused.gif)
When I service an engine with a head gasket swap I'll do a photo guide - it's not complicated
![geek geek](./images/smilies/icon_e_geek.gif)
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
Living life on the edge, SuPposedly
-
- Posts: 10
- Joined: Tue Jan 14, 2014 11:20 am
- My Bike: zxr 400
Re: Head Gasket help!!!
Yeah the half bearing bolts, are they supost to be changed? All of them stopped getting tighter but carried on going round… so I stopped checked the torqe on the rench again and carried on then one snapped, getting it out should be no problem but if I can not do them up to 12nm then what do I do??? And yes I have worked on other engines all previous bikes mostly 125s also done a lot with cars but that is Irelevent I have done them up to the torqes sai to be correct on this forum and they have snapped I am asking for advice not ridicule
- banner001
- Track day God
- Posts: 2589
- Joined: Sat Sep 24, 2011 3:27 pm
- My Bike: ZXR400 L4
- Location: Nuneaton
Re: Head Gasket help!!!
you need to do the cam cover bolts a little at a time in order to apply even pressure to the camshaft as it pushes down - remember, some of the lobes will be pointing downwards, you need to overcome that opposite force slowly. i finger tighten all the bolts, then give them each a full turn in a criss-cross pattern (like when doing the head) until they seat, then i torque them. never had a problem this way.
as im curoius, did you start the engine first time knowing that you had a potentially loose cam cover due to a sheared bolt, or did this happen on inspection after you got the rattling noise?
as im curoius, did you start the engine first time knowing that you had a potentially loose cam cover due to a sheared bolt, or did this happen on inspection after you got the rattling noise?
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said![:smt003](./images/smilies/003.gif)
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said
![:smt003](./images/smilies/003.gif)
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- Posts: 10
- Joined: Tue Jan 14, 2014 11:20 am
- My Bike: zxr 400
Re: Head Gasket help!!!
the bolt sheered off after taking the bike back apart.. i was putting it back together again
and the rattling noise was the cam chain tensioner after being taken out it no longer works so a new one
is on the way from kawasaki it will be back togther in no time
and the rattling noise was the cam chain tensioner after being taken out it no longer works so a new one
is on the way from kawasaki it will be back togther in no time