New Track Bike

[U_h0rnet5]

Hey Guys,

Been on a few track days nows and going to try start racing next year so got myself a project of building my own race bike!!!
I've started to gather a few of the smaller pieces together like coils, reg, cdi unit and that. Got myself a ZXR400L frame in good condition just needs a bit of a clean up. Already got enough tyres as from the track days slicks and wets. Just really need some Yokes so I can get it into a rolling chasis.

Today got my 2004 engine off eBay which the Head Gasket has blown. My mate and I have stripped it down (first one ive done which was fun and not as bad as what I would have thought) ordered the new gaskets should be coming at the end of the week! Dont really know what else to do with the engine apart from run it standard?

See how things go at the end of the week when hopefully rebuild it again and start building my track bike!!!

[zimm]

zxr400 engines can be assembled without the base gasket (between cylinders and cases) to slightly increase compression and tighten up the squish band.. just use a smear of silicon instead, slot the pickup for the ignition so you can advance the timing by 3 or 4 degree's, neither of these will transform the bike, but should make it "punchier" and , they're free !

matching the inlet rubbers to the ports in the cylinder head will only take 15 minutes with a dremel and pays dividends as they are too small when new, and shrink further over time.

what exhaust are you running ?

if OE, cut the link pipe off and replace with a straight through tube and fit a universal slip-on can, again, cheap/free performance gain compared to £400 + for a new exhaust system to gain you 2-3 bhp.

good luck with the project

[U_h0rnet5]

Hey cheers zimm, getting the gaskets today as they have come in so should be able to start to rebuild the engine. Got to clean up the pistons and cylinder heads as there is quite a bit of carbon build up on them!

Anybody know what i should use to clean them up with and how???

I've got a limited knowledge on engine/rebuild kinda being taught by my mate at the mo lol. Kinda understand most of it but some of the technical things I have not really got a clue!

Well I have not thought about the exhaust yet but was probably going to get a stainless steel one like the one already on my road bike which i got from SandyBikeSpares. But recently looking at it with the end can off it has got a kind of baffle in the like pipe. So i will probably go with your idea on cutting it off and replace it with straight like pipe and slipon can. Is there any problems with doing this??

[zimm]

its what my H is running and it works well, as good as the micron systems ive had at least, and apparently better than micron on a tuned engine, albeit a ton heavier and still liable to rot.



cept its now got an oval carbon akrapovic can on it

[unclesparks]

Good luck with the engine rebuild, ive got a feeling ive got to do the same on mine as its rattling like a bugger, getting a mechanic to tell me if its cam chain, tensioner or tappets. Knowing my luck all three. May see you at a Brands Track day. I read the thread about the link pipe, Im just worried about the noise and getting there and not passing the noise level check. Mines running a race Quill exhaust end can so its bloody loud at tick over let alone well i rev it.

[U_h0rnet5]

Hi yea might be waiting a bit for Brands. Going back to Cadwell for an open pit lane on 25th June. Trying to get as much track time as i can before next year.

Hopefully its just the head gasket gone, probably aint but if thats the case ill prob send it off to get blueprinted or something! (I'll get some pics up in a couple of days of the cleaning and rebuild)

Yea well my stainless steel exhaust with a carbon ART can on pushed 102dB which is only just under the requirements thats on my road bike which I've used for a couple of track days. I will prob go with the same set up just to get started can always change it at a later date. Might even have a look at Jap4Performance and check out the race exhausts??

[U_h0rnet5]

Right started to put the engine back together and already its frustrating me! :smt013

Just how do you put the cylinders back into their sleeve? Somehow i need to sprout another 6 hands to pinch the rings in and then put the top over them just can see that really happening.

[zimm]

hahah .. fun isnt it ..

ive just done mine this afternoon, and i've got to say whilst there's a knack to it, it's always a frustrating and fiddly job ..

i normally rotate the crank so that pistons 2 and 3 are close to TDC and get them in first then slide the block down a couple of cm, rotate the crank again to bring the pistons all a bit closer to each other then attempt 1 and 4, doing all 4 at the same time is nigh on impossible, and if you do 1 and 4 first you cant get your hands on 2 and 3 to pinch the rings into place ..

keep an eye on the oil rings (bottom), they can get snagged very easily and wreck bore/piston and themselves.

[cargo]

Easy peasy way is to fit the piston and cod rods one at a time into each bore then set the crank case on to the barrel.
Then set the crank into the crank case and line up the codrod ends with the crank pins.Then fit each codrod cap, normally I do the middle two then turn the crank and do the outside two.

You will need a block of wood to support the crank case but believe me this works

Much easier then trying line up all four and compress rings etc etc etc

[U_h0rnet5]

Cheers yea that did work a treat thanks with a little fiddling around. My dad came out and gave me a hand aswell after he hear the many of very nice words I was shouting :smt076 lol!

I would put some pics up but i cant and have not the tag on the options.

Just got the timing chain to sort out, put the top part on, the cams and then the rocker cover. Then all back together again !

I then start on the clutch and going to change the flywheel to a new lighter one!

[zimm]

Easy peasy way is to fit the piston and cod rods one at a time into each bore then set the crank case on to the barrel.
Then set the crank into the crank case and line up the codrod ends with the crank pins.Then fit each codrod cap, normally I do the middle two then turn the crank and do the outside two.

You will need a block of wood to support the crank case but believe me this works

Much easier then trying line up all four and compress rings etc etc etc

yeh, if you've got the crank out .. i thought he was just rebuilding the topend.

[U_h0rnet5]

Hey guys i wonder if you know which way the cam shafts go in? Silly me move them about and dont know which way round to put them

I know they are marked 'EX' for the outlet and 'IN' for the inlet! So would this mean that the 'EX' one would be placed on the exhaust side of the engine towards the front of the bike and the 'IN' one would be placed at the back end of the engine towards the back of the bike???

[cargo]

yes thats right

[U_h0rnet5]

Cool just thought id check before hand as i dont want to mess it up and my mate that i normally ask is in Thailand for his honeymoon not really the right time to ring and ask him lol!

[U_h0rnet5]

Just found out how to put pics on this post lol! Some of whats been happening with the build.