www.zxrworld.co.uk

Hi all..

Lilmike as im known and liveing in Manchester.
Had my 59plate suzuki gsxr600 stolen a week before xmas
When i finally got paid out on the ins, i searched and bought myself a rather nice looking
Kwak zxr400L1 1991 from a lad darn sarf..
Fetched it home, waited for the weather to get better, and it did eventually
So i took the lilbeast from the east on a trackday at Oulton Park after a breif get to know the bike rideout a day earlier
Love the bike... but its now in my shed undergoing a big service by myself, as it has developed rattles from the topend/cam chain and clutch
Shes a lovely bike, rides well and im impressed with the 20 year old after rideing newer bikes the past few years
Im running Avon Ultra supersports after disgarding the tyres that cam on her as they were over 10 years old and badly squared off ( only done a recorded 18.000 not ridden hard mls ) after scrubbing in the Avons at Oulton Park and redlining the bugga for several sessions, well things had to give i guess
After a clutch rebuild, tappets reshimmed, and cam chain,runners checked replaced and carbs balanced, she will be in fine fettle once again and ready for the spring/summer roads and tracks
Cant wait..
Im hopeing for some good advice/help and tips as i inspect and redo a few worn parts

tried to post a pic of said zxr, but cant for some reason ? do i need to use photobucket ?

photobucket or a gmail account work fine for me.

as for rattles, the zxr HAS a rattly clutch even from new...but fresh pads, steels and springs and you know your good for a while.

check that the cam chain tensioner blade has not broken...a bit of a weak point on these bikes, if its broken stick a new chain on and do the valve clearances.

if you are going to race the bike regularly, depending on the miles its done, consider (as you will have the engine already out to do the cam chain) replacing the piston rings, get the barells re-honed, and lap the valves/re-grind if they are bad.

now, pics up manc lad

Hi banner

I took the clutch cover off and removed the friction plates and steel plates, measured them and the steel plates are fine, but the friction plates are worn enough to warrent replaceing and the springs are not quite std length. The hub and basket are fine and no marking/grooves on the fingers, so ive just ordered a complete clutch replacement kit EBC SRC with kevlar friction plates and heavy duty springs ( the clutch bite will be differant from std i know, but i will get used to it )
One thing i did notice whilst removeing the clutch plates, the whole hub and clutch assembly had slight movement in it, even before removeing the plates is this normal, im only talking a 1-2mm of movement as if the clutch hub nut needed re torqueing ? all stuff to check

The pulsor cover is off, but i havent the time ( work nights ) to fully inspect the chain and tensioner, tommorows job
The top end is tappy but not horrific, but whilst its in bits ie fairings off etc etc i may as well remove the rocker cover etc and check the clearences.
I was told, doing the carb balance some times reduces the topend tapping noises ?

Ive taken pics on my phone, at each stage of dismanteling the bike so i will upload them to photobucket or gmail at some point
http://i1280.photobucket.com/albums/a48 ... 643a27.jpg

arent kevlar plates only for racing use? i though they didnt get warm enough for road use and are very "on/off" in road use...you might wanna check into this.

banner001 wrote:arent kevlar plates only for racing use? i though they didnt get warm enough for road use and are very "on/off" in road use...you might wanna check into this.

yes your right, they are quite on/off for road use, but i will be doing quite a bit of trackday riding and progressive road riding.
Already bought the kit now.. going to make town riding fun
if the clutch is far too harsh, i will get the std items and re-fit, there same price so i thought why not, it will spending most of its time at pace anyway once every thing is sorted
Its a learning curve.. i know, i should have asked on here first LOL

cant make that photobucket site out... im more use to facebook for my pics..