Engine re-fresh

[TyeNoodle]

I've been tasked with re-freshing the engine in the zxr over winter.

Camchain is noisy so that needs doing, will do valve clearances etc as a matter of course. Aside any damage found, what does everyone usually replace/check on a winter rebuild?

Its a fairly tuned engine, 72hp or somewhere near..

Cheers!

[TyeNoodle]

Noone know/Sharing? Going to start the strip soon....

[jic44]

big end and main bearings, piston rings, pistons inspected replaced if necessary, hone the cylinder if necessary, measure valves replace if necessary re seat if not, replace valve stem seals, measure valve springs and replace if necessary... loads more i cant think of right now but that'll get you started

[jic44]

a set of collets can be a good idea...... Obviously new gaskets all round... inspect the cam lobes and journals

[TyeNoodle]

Big job on then eh!

Are the big end and main shells replaced every year as a matter of course?

I need to get a manual I think, are the genuine ones easy to come by?

Thanks
Paul

[wes]

Depends on how many hours you do on the engine, I would have thought every other year.

As for the manual...this handy link to a site near here!
http://www.zxrworld.co.uk/zxr400/manual.html
Download all 3, as the L is a supplement to the H manual, and the racing kit manual is interesting too

[TyeNoodle]

Hey cheers for that!

It had a rebuild last winter, according to the previous owner. Unsure if there are reciepts, until I see them I'll assume it's not been done for a while!

It was going well until a spill at 3 Sisters where the bike ended upside down for a bit, it also ditched all of it's oil so I'm wondering if some damage has been done, especially as it wasn't going so well after that incident..

[jic44]

im in the process of doing my own at the moment and its not that hard a job really. if its your first time just take it slow and give yourself a good clean space to work in