Bike needs:
Forks, yokes (top and bottom), radiator engine mount (LHS), clip ons, wheels, spindles/spacers, cush drive, sprocket carrier bearing etc.
Basically a bitsa comprised mainly of what we found on my mate's garage floor:
I am reliably informed there are at least FOUR ZXR's or ZX400's in there.
See if you can spot em ..!Since its a shitter, theoretically, we are going to tune the monkey's nuts out of it.
Ported, gas flowed, skimmed head running race system and compression without a base gasket on dual electrode sparks for starters ..
Here's the prelim strip, cleanup and prep for porting.
The engine is unearthed from beneath a mound of debris. Its an H2 from 1990 that was part-exed ages ago and is known to have a blown head gasket.
I ordered a new camchain and head gasket from Cradley Kawasaki for the job.
Staggered by the prices: £11.75 for the gasket and £19 for the cam chain!
The blown gasket means all the oil has turned to toad with coolant. Its then been stood in a garage for months .. possibly years ..
We stripped off the head and found the camchain to be new, the cam journals mint, the rockers spotless and the bore spotless.
Looks like the engine has either had a complete rebuild or was blown, flogged, broken then forgotten about .. The clocks that came with it read 40k kilometers so we can probably assume thats a genuine mileage, on a 17 year old import! Not bad.
^ You can see clearly where its blown the head gasket. Note spotless piston crown. It was because the bore had filled with coolant. Yum.
I stripped out the valves and cleaned the head with paraffin and a jet washer..
Head nice and clean, I leave it to drip dry in the seasonal afternoon sunshine and go back inside to check out the flywheel and clutch.
The clutch is surprisingly gunk free ..
The flywheel rotor magnets are fecked. Massive crack in them means its got to be pulled and replaced with a spare from downstairs ..
Thats pencilled in for later on when the engine is back in the frame.
I drop the sump in a bid to flush out as much ganky toad as possible before rebuild and to check the internal filter for any blockages ..
Euuuuq. Manky toad!
Even the dog is disgusted!
I nip it downstairs and pressure wash the nuts off it!
Thats better!
I wash the filter out and re-install it .. the rubber has perished with age so we use some RTV silicon sealant to help keep it in situ.
Gear selector drum, dogs, and the gearbox all look spanking! Very clean for a 17 year old ..
Head is drying nicely in the sunshine ..
As it starts to get dark I bring it inside and clean up the workspace ..
Now its over to Zimm to do the porting ..
I slink outside to jet wash the ZZR while all the stuff is out ..
More to come! Including a ton of videos ..!
