ZXR400 H1 race project
Posted: Fri Mar 28, 2008 8:13 pm
Hello everyone, im motorsport engineering student in brooklands college, weybridge.
Ive got a proper mission to do here, building a 400cc race bike which ive never done before. I have actually done few things in the past, back when i was in indonesia, building 125 race track bike, and that was a success, got the bike run up to 140 mph in the end....
Yeah btw, I have chosen to do this year project on my ZXR400 H1 model which has bad engine (Has done 33,000 miles) and cooling system problems, it just leaking everywhere...
Well bought the bike on ebay, so the consequences is taken, lol...
Here is the picture of the bike after its being washed...
The bike does look mint, but the performance doesnt... When it runs, the engine sounds very rough...
First of all, i took the bike for dyno test, but before start dyno testing, i took one last picture with the bike just in case it blew up when running on dyno....lol..
Dyno test shown that the bike has misfiring problem, it produced 42.9 bhp at 9800 rpm and flat range torque.
Then i stripped the fairing off...
Then i inspected the engine condition, found out that the head gasket is leaking badly, leak around the water pump, cracked coolant bottle, etc2...
So i took the engine off the bike
Then i stripped the engine down,
When i took the cylinder head off, i found out that the piston rings were in very bad condition, I could easily feel the play on the piston when i wobbled the piston side to side by hand while its still in the bore. Then i took all the valves off....
Then i measured all the engine components to check for wearness....
I compared the results with the minimum service that shown in the manual, Not surprisingly, all components were below the minimum service condition...
Especially the valves, they were badly worn....Luckily the cams, pistons, conrods, crankshaft, bores and rocker arms were still in good conditions....
Til now im still thinking 'what made me think to buy this bike!!'....grrrrrr.......
Ive got a proper mission to do here, building a 400cc race bike which ive never done before. I have actually done few things in the past, back when i was in indonesia, building 125 race track bike, and that was a success, got the bike run up to 140 mph in the end....
Yeah btw, I have chosen to do this year project on my ZXR400 H1 model which has bad engine (Has done 33,000 miles) and cooling system problems, it just leaking everywhere...
Well bought the bike on ebay, so the consequences is taken, lol...
Here is the picture of the bike after its being washed...
The bike does look mint, but the performance doesnt... When it runs, the engine sounds very rough...
First of all, i took the bike for dyno test, but before start dyno testing, i took one last picture with the bike just in case it blew up when running on dyno....lol..
Dyno test shown that the bike has misfiring problem, it produced 42.9 bhp at 9800 rpm and flat range torque.
Then i stripped the fairing off...
Then i inspected the engine condition, found out that the head gasket is leaking badly, leak around the water pump, cracked coolant bottle, etc2...
So i took the engine off the bike
Then i stripped the engine down,
When i took the cylinder head off, i found out that the piston rings were in very bad condition, I could easily feel the play on the piston when i wobbled the piston side to side by hand while its still in the bore. Then i took all the valves off....
Then i measured all the engine components to check for wearness....
I compared the results with the minimum service that shown in the manual, Not surprisingly, all components were below the minimum service condition...
Especially the valves, they were badly worn....Luckily the cams, pistons, conrods, crankshaft, bores and rocker arms were still in good conditions....
Til now im still thinking 'what made me think to buy this bike!!'....grrrrrr.......
