H2 Restoration, tune and re-spray.
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- zxr400 oc member
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- My Bike: kwack ZXR750L1
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Re: H2 Restoration, tune and re-spray.
its the trying to get panels AND painted bit that i dout...
if you've got time most of it dosent look to hard to sort!
if you've got time most of it dosent look to hard to sort!
ZXR750 L1
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
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- zxr400 oc member
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Re: H2 Restoration, tune and re-spray.
Well I think I have found out why the fuelling is all over the place.
The carb drain plugs (bottom of float bowl) are leaking fuel even when done up fully.
Must be the source of the air leak!
Explains why adjusting the idle mix screws isnt solving the surging.
Grr.
Hopefully just needs some o-rings ..
The carb drain plugs (bottom of float bowl) are leaking fuel even when done up fully.
Must be the source of the air leak!
Explains why adjusting the idle mix screws isnt solving the surging.
Grr.
Hopefully just needs some o-rings ..
zxr400 h2 (breaking)
zzr1100c3 (broken)
Vespa et4 (almost broken)
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"Save the planet, eat a vegan .." - Clarkson
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- zxr400 oc member
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Re: H2 Restoration, tune and re-spray.
Already got some panels ..rene wrote:its the trying to get panels AND painted bit that i dout...
if you've got time most of it dosent look to hard to sort!
All differet colours mind you but at least they make a set.
The left hand one has melted somewhere and been patched the right is split.
zxr400 h2 (breaking)
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
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- zxr400 oc member
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- Joined: Fri Feb 23, 2007 10:34 am
- My Bike: kwack ZXR750L1
- Location: Northampton
Re: H2 Restoration, tune and re-spray.
well i guess your all sorted then :smt013
Have you checked your floats arent sticking ?
Have you checked your floats arent sticking ?
ZXR750 L1
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
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- zxr400 oc member
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Re: H2 Restoration, tune and re-spray.
Yeah they're ok ..rene wrote:well i guess your all sorted then :smt013
Have you checked your floats arent sticking ?
I just soldered the holes up and its much better.
Still surging a little but nowhere near as bad.
I reckon another half turn out on the idle mix to 3 turns will do it.
Having this issue because when we ported the head we also enlarged the intakes quite a bit ..
I really should get a bigger pilot jet but I'm too tight.
zxr400 h2 (breaking)
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
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- zxr400 oc member
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Re: H2 Restoration, tune and re-spray.
Yay fixed the fuelling.
Made some shims for the needles to give it a bit more umpf in the mid range:
Thats basically made from a plastic milk carton and adds 1.1mm to the needle height.
Which has given the bike considerably more go - it was running very lean on the ported and enlarged intakes.
Also plugged all the holes down below around the drain screws with silicon and solder.
Idle screw is now a whopping 3.5turns out (!) but it idles and revs freely.
Sorted.
Now onto the starting issue ...
Made some shims for the needles to give it a bit more umpf in the mid range:
Thats basically made from a plastic milk carton and adds 1.1mm to the needle height.
Which has given the bike considerably more go - it was running very lean on the ported and enlarged intakes.
Also plugged all the holes down below around the drain screws with silicon and solder.
Idle screw is now a whopping 3.5turns out (!) but it idles and revs freely.
Sorted.
Now onto the starting issue ...
zxr400 h2 (breaking)
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
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- zxr400 oc member
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- Joined: Fri Feb 23, 2007 10:34 am
- My Bike: kwack ZXR750L1
- Location: Northampton
Re: H2 Restoration, tune and re-spray.
bloody hell thats a bodge and a haf lol nice work really good idea!
ZXR750 L1
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
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- zxr400 oc member
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- Joined: Mon May 07, 2007 11:38 pm
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Re: H2 Restoration, tune and re-spray.
Ok in the end it was 4 turns out ..
All is well.
Now I think I am going to fall down trying to find this electrical fault.
The reg/rect is getting very hot, which would suggest a short somewhere.
The starter motor is turning over pretty slowly even on full battery.
The charging circuit is working fine, 14.5v at 2, 000 rpm etc
The issue must be in the starter circuit
All is well.
Now I think I am going to fall down trying to find this electrical fault.
The reg/rect is getting very hot, which would suggest a short somewhere.
The starter motor is turning over pretty slowly even on full battery.
The charging circuit is working fine, 14.5v at 2, 000 rpm etc
The issue must be in the starter circuit
zxr400 h2 (breaking)
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
- RedexRobB
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Re: H2 Restoration, tune and re-spray.
The rectifier will get hot, thats why its got cooling fins on it.
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- zxr400 oc member
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Re: H2 Restoration, tune and re-spray.
Ok been trying to find the problem with the hot starting.
TBH the starter sounds lazy even when cold and on a full battery so I starter by checking the battery - a good 12.6v
Then I checked the starter relay and at the live end its getting 12.5v, again ok.
Checked the cable that connects the starter relay to the starter motor for breaks:
That seems ok ..
So the starter relay is working and the starter motor is getting 10.8v+ fairly consistently.
Until the bike gets hot, when the voltage drops right off.
I thought since the bike is new to me I'd dissect the starter motor anyway and have a look:
Brushes are mint:
Service limit is 3.5mm, standard is 7.0mm. This motor is as-new.
Again perfect ..
Checking the resistance ..
OK
OK
OK
Summary?
The starter motor is practically new, is obviously a replacement or refurb or has never been used for more than a few thousand miles ..
Its hardly worn at all, in some cases, literally not at all.
The issue must be electrical so the next stop is the loom!
TBH the starter sounds lazy even when cold and on a full battery so I starter by checking the battery - a good 12.6v
Then I checked the starter relay and at the live end its getting 12.5v, again ok.
Checked the cable that connects the starter relay to the starter motor for breaks:
That seems ok ..
So the starter relay is working and the starter motor is getting 10.8v+ fairly consistently.
Until the bike gets hot, when the voltage drops right off.
I thought since the bike is new to me I'd dissect the starter motor anyway and have a look:
Brushes are mint:
Service limit is 3.5mm, standard is 7.0mm. This motor is as-new.
Again perfect ..
Checking the resistance ..
OK
OK
OK
Summary?
The starter motor is practically new, is obviously a replacement or refurb or has never been used for more than a few thousand miles ..
Its hardly worn at all, in some cases, literally not at all.
The issue must be electrical so the next stop is the loom!
zxr400 h2 (breaking)
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
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- zxr400 oc member
- Posts: 355
- Joined: Mon May 07, 2007 11:38 pm
- My Bike: ZZR1100C3
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- Contact:
Re: H2 Restoration, tune and re-spray.
Since I was in the shed due to rain, I decided to strip the clutch as well in preperation for getting the basket bearing changed next week ..
You can't see it in the picture but the basket literally tilts 30 degrees on the bearing - its utterly fecked.
I'm waiting for my clutch holding tool to arrive off ebay ..
More to come here.
I also am expecting a flywheel from another ebayer to replace the cracked one on the engine.
You can't see it in the picture but the basket literally tilts 30 degrees on the bearing - its utterly fecked.
I'm waiting for my clutch holding tool to arrive off ebay ..
More to come here.
I also am expecting a flywheel from another ebayer to replace the cracked one on the engine.
zxr400 h2 (breaking)
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
zzr1100c3 (broken)
Vespa et4 (almost broken)
My FleaBay
"Save the planet, eat a vegan .." - Clarkson
- masterofinsanity
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Re: H2 Restoration, tune and re-spray.
nice one mate keep us updated on that electrical gremlin!
Don't forget people there is more to the zxr400 than this forum... check out www.zxrworld.co.uk also.
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- zxr400 oc member
- Posts: 1918
- Joined: Fri Feb 23, 2007 10:34 am
- My Bike: kwack ZXR750L1
- Location: Northampton
Re: H2 Restoration, tune and re-spray.
wish i had a digital mesure thing (forgten the name)
the way i get around the clutch tool is if you put one of the bolts that holds the clutch caseon in then wedge a screw driver bettween the screw and the teeth holds it fine!
admitadly you normaly need 2 people to do this. Get some EBC race friction plates while you've got it striped trust me it makes a world of diffrence!
the way i get around the clutch tool is if you put one of the bolts that holds the clutch caseon in then wedge a screw driver bettween the screw and the teeth holds it fine!
admitadly you normaly need 2 people to do this. Get some EBC race friction plates while you've got it striped trust me it makes a world of diffrence!
ZXR750 L1
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
- masterofinsanity
- Site Admin
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- Joined: Thu Aug 29, 2002 12:36 am
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Re: H2 Restoration, tune and re-spray.
a vernier they are about a fiver nowadays, when i bought mine about 15 years ago they were £90rene wrote:wish i had a digital mesure thing (forgten the name)
Don't forget people there is more to the zxr400 than this forum... check out www.zxrworld.co.uk also.
-
- zxr400 oc member
- Posts: 1918
- Joined: Fri Feb 23, 2007 10:34 am
- My Bike: kwack ZXR750L1
- Location: Northampton
Re: H2 Restoration, tune and re-spray.
i've got one older than that....most of my tools are hand be downs from my dad so its about 30 odd years old lol its a nightmere trying to get a good mesurement off it!
ZXR750 L1
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/
tail tidy, polished bits, custom paint job, k&n, dynojet, Full akropovik, down geared, GSXR calipers, hel brake lines front and rear & clutch line, maxtron resprung froks 120BHP
BikePics page-
http://www.bikepics.com/members/zxr400rene/