www.zxrworld.co.uk

A really useful website so I thought I'd better join and join in! I've had my ZXR400 L4 from new in 1994. I used it a lot until 1997 (best bike, summer use, had a tatty hack for commuting to work year round), lots of race meetings and a couple of years to the TT. Loved it. Then various changes of interests, personal life and work circumstances meant that I stored it away and kinda got on with other things in life. I didn't need a bike for work, getting a job close to home, and got into mountain bikes.

Fast forward to a few months ago. I started to take car driving lessons in readiness for a change of job - hated it! I'll do the test as it is a useful skill to have but I have no interest in driving a car, it seems so clumsy. What the lessons did do, strangely enough, is reinvigorate my interest in bikes. If I'm going to be motorised I'd rather drive something fun. So I decided to get the ZXR out and get it sorted for next spring.

I've done quite a bit to it so far but am now waiting for the better weather - it's a bit cold working in the garden right now! All the fuel was drained out of the tank and carbs when it was stored in a dry shed years ago, so I don't expect a lot of gunky problems there. The sump has been drained and the oil (Silkolene fully synthetic) which came out looked very clean with no water in it. The coolant has been drained and the system flushed ready for refilling - again looked clean. Colant hoses look fine. New battery obtained - the old one had been removed when stored. The brake fluid looked like treacle and the front brakes were binding. All the brake hoses front and rear have been stripped, master cylinders stripped and rebuilt with new pistons, front and rear brake calipers stripped down, cleaned, new seals fitted, and new Hel braided hoses obtained. Everything on the brakes will be reassembled in the spring - no point having fresh brake fluid sat about all winter. All fuel lines have been replaced. Air filter cleaned. Tyres look sound.

The bike had done 8500 miles when put away. At 6000 miles or so I had the camchain jump and this was replaced - luckily (amazingly) I never bent a single valve! Seems like the camchain is an issue with this engine. So when I get everything sorted and back on the road the bike should be in very good condition for its age with loads of years left in the engine.

One good thing with getting a bit older (42) is that when I last insured the bike I could only afford TPFT with a full 5 years NCB. When I got a quote the other day, with no NCB (as I've been off the road) Fully Comp was half the price I was paying for TPFT 13 years ago!

Issues I am expecting when I come to start it -

First it will get a bit of oil down the plug holes a couple of days beforehand. Then it will be cranked over with no fuel several times with a rest between to get oil pumping round the engine. After it starts it will be run for a minute or so before stopping for 15 or so. That should get the oil right round and then I'll start it again and let it idle for a while.

Second - I do anticipate hassle bleeding the brakes when the new kit is fitted but I've read a lot of stuff on this and am pretty handy with the spanners and I think I can crack it.

Apart from that we'll have to see. It was running mint when put away so considering the decent environment it has been in if it will fire up I expect it to run ok. If it won't fire up we'll have to see why - cross that bridge etc.....

So, might see some of you in the spring. The bike is pretty standard apart from Pirellis front and rear, Ferodo pads on the front (much better than anything EBC make, I've used Ferodos on several bikes taken to the IoM and would HIGHLY recommend them) - original pads on the back as I never use the rear brake, and soon to be Hel hoses. When I got the bike I adjusted the rear shock to decrease the pre-load as much as possible. I'm not very heavy and it was like a brick before and the tyre skipped on bumps. With it set as it is I've never had a problem with it, it's firm but firm is good. In the meantime, some pics......

ooooooooooooo that looks nice!! welcome to the forum!

Thats amazing! welcome to the forum!

All sounds very sensible what your doing except id say get some new tyres on as they will no doubt have gone off, an old tyre even with low mileage on them will feel crap. I had a 7 year old tyre on the back on my 7R (very little use by previous owner) and that felt awful, but didnt realise till i changed the tyre how awful!

I'll see what they feel like once I get it on the road. If they are nasty they'll have to go. It'll be a shame mind you, there's loads of miles left on them but there's no point sticking with them just for the sake of it if they're off.

Incidentally, I always used to put premium unleaded in it before but I notice that most of the garages don't seem to have it on the pumps now. Do you reckon it's worth tracking down or is it a waste of money? I always figured why buy a high performance bike and then not put the highest octane fuel in it, but if it makes no difference.......

im pretty sure there has been a thread on this before....think jamz might have done it....i personally always put the higher octane fuel in the bike.all the major brands bp, shell etc always have the higher octane fuel.

Good read and welcome to the site

Agree with Rob - bin the tyres, don't even think about it - they will be well past their best ! Don't want to be going for a slide on such a nice example of a 400

With you doing all new fluids I would be more tempted to get out and use the bike rather than fire it up and switch off then fire it up again. You don't need to go far - short curcuit around where you live and sensible throttle use

Squirt light engineering oil down bores rather than engine oil - it will burn off quicker and less likely to foul your new plugs. Check all your electrical connections especially earths for corrosion - no harm in pulling them and spraying with contact spray.

Make sure you get the engine up to temp (you want the fan to come on at least once) before stopping for the day , you want all the internals to get up to temp and cool evenly. No harm in putting some carb/fuel line cleaner into your first tank full , I have high octane in the bike just now but doesn't seem to run as well in the cold temps just now (I do use in summer) so will go back to standard on next fill.

Keep the photos coming and your progress getting ready for Spring

ATB,

MM!

http://zxrworld.co.uk/zxr400oc/viewtopi ... 57&t=11425 might interest you

Thanks for the advice guys, good stuff.

I don't think the electrics should cause me any problems. I had a good root round and they look very clean. The shed it has been in is dry and the bike generally has suffered no corrosion. I had also had it covered with a canvas bike cover and dustsheet (I don't like plastic covers, I reckon they trap the damp in).

Do you really think I need to change the plugs? Why would they have deteriorated, being just metal and ceramic? I was going to clean and gap them and reuse them.

Point taken about the tyres. I've had a look elsewhere on the internet and there are some nasty stories about old tyres, so I'll order some new Pirellis.

While I had the calipers in bits I noticed a few areas of bubbled paint and the beginning of corrosion, so I decided to do a repaint - there won't be a better time. Having failed to find a match for the original colour, and having bought purple Hel hoses, I decided to paint them black instead. The car shop didn't have caliper paint in gloss black, just matt, nor high temperature paint in gloss black - every colour except. So I got a can of Hycote gloss black engine enamel which produced excellent results with no runs as you can see
I also put a new oil filter on, Champion F306 from Halfords was cheaper than OEM and arguably better quality.

That's it for now until it starts to go back together.

Tirpitz wrote: Do you really think I need to change the plugs? Why would they have deteriorated, being just metal and ceramic? I was going to clean and gap them and reuse them.

Point taken about the tyres. I've had a look elsewhere on the internet and there are some nasty stories about old tyres, so I'll order some new Pirellis.

Like most things time deteriotes even spark plugs, apart from that I have had a brand new set fail instantly - they could have been stored badly or been in the shop for months/years. It's not a wreck of a bike so why try save a few pounds on a cheap service ?

Tyres are date stamped for that very reason , look out for bargain buys on EBay (my case Yahoo) as that's where 6 month old tyres usually end up - a shop should not sell a tyre over 1yr from manufacture and most only keep stock of sizes they know they shift quickly.

Just had the BT090 changed on the ZRX and it was only 2yrs old and had done about 5,000 miles . Was on it's wear indicators (about 1mm left) still had a good profile but road feel felt crap, inside the tread pattern was full of creep , new BT92 on and front end has transformed

MM!

Just a little update to show I'm taking notice of the advice like a good boy

Binned the 13 year old Pirelli Dragons, got a pair of Diablos fitted this week. I see what you meant - just the feel of the old tyres compared to the new ones was worrying

Listened to MoriMan and when I had the plugs out I squirted a teaspoon of light general purpose oil down each bore. I've left it to penetrate, or whatever it's going to do in there, ready for when I turn it over in a few weeks.

I've given the missus the petrol can to get me some petrol next time she fills the car up. Then in about a fortnight I'll get the new battery filled and charged, put all the fluids in and see if she goes bang.

Then I've got te brakes to put back together....... and bleed So I may not be full of the joys of spring after that little job, if it proves to be a PITA.

And here's a photo of what it looks like so far