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Engine Top End Overhaul

Ask questions and discuss technical items here. Tighten till it strips, then back out a half turn.

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Buzz
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Re: Engine Top End Overhaul

Post by Buzz » Wed Nov 01, 2017 6:09 pm

And don't say. Who says you're ladies!!!! Buzz.

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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Thu Nov 09, 2017 10:34 am

Engine block is off to Motorcycle Masters for re-assembly with refurbished barrels, pistons and head.
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Re: Engine Top End Overhaul

Post by BillWest » Sat Nov 18, 2017 12:06 pm

Parts are back at Motorcycle Masters.
Pitting.jpg
Pitting on valve seat, before machining.
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PartsBack.jpg
The important bits.
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CleanedUpHead.jpg
Nice and cleaned up.
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LightlyHoned.jpg
Barrels honed to remove glazing.
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Tue Nov 28, 2017 9:58 am

Waiting on two sets of piston rings ...........
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Re: Engine Top End Overhaul

Post by BillWest » Tue Nov 28, 2017 1:08 pm

Meanwhile, this arrived today:
Headers3.JPG
Stainless, lighter, unrestricted
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Headers4.JPG
Headers4.JPG (258.38 KiB) Viewed 1221 times
The older headers:
Headers1.JPG
Kawasaki OEM, restricted
Headers1.JPG (239.75 KiB) Viewed 1221 times
Headers2.JPG
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Tue Nov 28, 2017 1:11 pm

Headers....
Headers5.JPG
Better flow in the new headers
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Headers6.png
The restricted area
Headers6.png (273.9 KiB) Viewed 1221 times
(I didn't cut mine up, btw, another WA ZZR owner cut his).

The new headers also don't have the mesh type wall, so a smooth flow is guaranteed.
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Sun Dec 10, 2017 7:38 am

Word is that the 2 sets of piston rings will arrive mid-week.

Meanwhile:
Head2.jpg
All tidy.....
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Buzz
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Re: Engine Top End Overhaul

Post by Buzz » Sun Dec 10, 2017 10:14 pm

I bet you can't wait Bill. Buzz.

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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Fri Dec 15, 2017 3:22 pm

Eureka Stockade!

Rings have arrived, pistons are in, barrels are on. New base and head gasket. Head is in place, camshafts and chain fitted. Final shim check, and the lid goes on.
Pick up most likely tomorrow morning - trailer the bare bike in, fit engine in frame, trailer it home.

Then the fun continues, fitting all the other bits and pieces on and in. I hope I won't have any bits left over ....
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Sat Dec 16, 2017 12:14 pm

On the workbench at Motorcycle Masters.

Top end done!

CamsIn.jpg
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LidOn.jpg
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Sat Dec 16, 2017 12:27 pm

Off to MM to have engine fitted.
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EngineIn1.JPG
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EngineIn2.JPG
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Sat Dec 16, 2017 12:30 pm

Home again ..
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HomeAgain.JPG
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Buzz
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Re: Engine Top End Overhaul

Post by Buzz » Sat Dec 16, 2017 8:39 pm

See it tomorrow Bill. Buzz.

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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Thu Jan 04, 2018 8:04 pm

A bit of an hiatus, what with having to attend XMas functions here and there, having to paint eaves and carport, and even having to go away for the New Year's weekend to Hyden and Esperance.
Esperance2.jpg
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Thu Jan 04, 2018 8:19 pm

However, today was a good day to continue assembling the bike. With the engine in the frame, came the time to attach various bits and pieces, starting with frame members, nuts and bolts, including the infamous castle nut farkers that I had so much trouble removing.

First step was to attach the front sprocket and chain.
SprocketOn.JPG
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Next was the tightening and torqueing of various nuts and bolts.
All went well until I discovered a stripped nut on a rear engine bolt, the result of a previous tightening effort by an unnamed Dealer and Workshop some years ago.
Stripped.jpg
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Fortunately, the bolt had not stripped. What is seen in the bolt thread is actually what stripped out of the nut. The nut has been replaced, the bolt cleaned, and torqued to the correct setting.

I have since discovered another stripped item - a frame bolt (steel) inserted in to an alloy frame member. Guess which bit is stripped? I am procuring a longer frame bolt, and will put a washer and nut on the other side (it actually goes through the frame member and comes out the other side).

I also need a new spacer for my clutch slave cylinder. This part, of course, has to come from the Eastern States.
Spacer.jpg
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To be continued .....
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Mon Jan 08, 2018 2:08 pm

Stripped bolt is sorted.
Bolt1.jpg
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Bolt2.jpg
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Clutch slave cylinder, sprocket cover and wiring done:
Covers.jpg
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More wiring connected and tidied:
Wiring.jpg
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Mon Jan 08, 2018 4:52 pm

New headers are on, as well as the mufflers.
HeadersOn.JPG
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MufflerLeft.JPG
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MufflerRight.JPG
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Tue Jan 09, 2018 3:22 pm

Radiator bracket broken ....
3 weeks from Japan.
Bracket1.jpg
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However, being a member of the CBMMA:
Bracket2.jpg
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Bracket3.JPG
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.... and so the radiator can be installed.
RadIn.jpg
RadIn.jpg (225.57 KiB) Viewed 1019 times

(CBMMA: Cheap Bastards Motorcycle Mechanics Association).
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Tue Jan 09, 2018 3:25 pm

Fuel pumps are in:
FuelPumps.JPG
FuelPumps.JPG (264.26 KiB) Viewed 1018 times
Soon, it will once again be:
Kwik.jpg
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Tue Jan 09, 2018 5:17 pm

Oil cooler took a bit of fitting (PITA) ....
OilCooler.jpg
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Hey Glenn, I found a couple of items, not sure where they go. Any ideas?
Extra1.jpg
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Extra2.jpg
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Fri Jan 12, 2018 9:53 am

IT issues with 3rd party (compulsory) providers have kept me away from my project for the last couple of days, and it is not resolved yet. All of this is related to the undesired but mandated "game" of electronic conveyancing. But, that is another matter.
Wine.jpg
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Image.
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Fri Jan 12, 2018 2:11 pm

LoveComputers.jpg
All is good once more ....
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Putting the rubber heat shields in the right way takes time.
Heatshields.jpg
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Carefully clean around the carbies with the wife's toothbrush (I couldn't find that at first, she had hidden it).
CarbClean.jpg
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Do we need de-icing tubes in WA?
DeicingTubes.jpg
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Nope!
NoDeicing.jpg
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What goes where ...
HosesWhere.jpg
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Relax Glenn ....

The outside one are for the now defunct de-icing circuit (blocked off).
The others are drains for the airfilter housing.
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Fri Jan 12, 2018 5:18 pm

Carbies are in, fuel lines from pumps, electronic wiring for fuel cut-off solenoids, ktric carb sensor wiring, idle adjuster, throttle cables, choke cable, are all attached.
CarbiesIn.jpg
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I purposely switched throttle cables and the way they attach to the carburettors, just so I could practice taking the carbies off, swapping the cables, and putting the carbies on again.
ThrottleCables.jpg
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BillWest
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Re: Engine Top End Overhaul

Post by BillWest » Sun Jan 14, 2018 4:20 pm

Next:

Oil, filter, coolant.
Fluids1.JPG
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Lolly water (coolant) made up.
Fluids2.jpg
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GlennR
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Re: Engine Top End Overhaul

Post by GlennR » Mon Jan 15, 2018 9:34 am

Looking very close to done Bill. But will it start?? It probably will, so I feel a bet money handover ceremony coming on . . . .

Glenn.

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