Here we go again! - ZX Forums
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post #1 of 42 (permalink) Old 12-04-2016, 03:59 PM Thread Starter
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Here we go again!

Any of you that read my last race engine build thread may remember that it ended in tears with a conrod breaking through the front of the engine casing then proceeding to rotate and destroy pretty much everything.

Not one to be beaten I have decided to have another go at it. I picked up a 68K mile running motor for 70 as a donor for my rebuild. Gears, oil pump and bits and pieces are being swapped with ones from a newer engine that has done less miles. Cylinders will be re-bored with new pistons, new rods... lots of other cool bits, so not really concerned about the high millage as it will be fully refreshed.

Pics tell the story so far, saves me typing it all up ;)














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post #2 of 42 (permalink) Old 12-04-2016, 04:02 PM
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YOU'RE F - KING AWESOME!!!
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post #3 of 42 (permalink) Old 12-05-2016, 03:05 AM
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Great stuff Ritchie!
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post #4 of 42 (permalink) Old 12-05-2016, 04:20 AM Thread Starter
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Thanks guys

This one is going a little bigger than 780 ;-)

I will be painting the cylinder block and head in the same black. Need to finish gapping the rings this coming weekend, then the pistons will be going in (if I have managed to paint in time).

Hopefully if CCM has the stock I should be running kit valve springs and retainers to go with my race adjustable cams.
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post #5 of 42 (permalink) Old 12-05-2016, 09:52 AM
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Watch out Golden Era!!!!
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post #6 of 42 (permalink) Old 12-11-2016, 01:07 PM Thread Starter
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So, you may have noticed the cam chain missing on the pics on my first post. I forgot to put it on the end of the crank before I put the case halves together. Its not possible to get it on when they are together, so I have to take it apart again, clean off all the sealant and re-assemble. Not quite sure how I forgot! Its in now and I can start moving forward again :)

Before I install the pistons I gave the cylinders and head a nice coat of paint too. Got to have things matching of course!


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post #7 of 42 (permalink) Old 12-12-2016, 02:14 PM
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It's looking good.

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post #8 of 42 (permalink) Old 01-02-2017, 01:23 PM Thread Starter
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Some more progress made. I was hoping to get it running by now, but other commitments have got in the way. Getting close to completion though:













Used a piston stop to find true TDC. Ready to get the cams in now to shim and degree :)

The rubber chain guide at the top the cam cover was missing when I took the cover off (seems to be common). I have a new one, but was wondering if anybody has used any adhesive when fixing these in? It does push on tight to the little stubby pins but I feel more than a push fit is necessary.
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post #9 of 42 (permalink) Old 01-02-2017, 01:45 PM
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Looking great! Stroker? Over bored?
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post #10 of 42 (permalink) Old 01-02-2017, 01:46 PM
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Nice job!
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post #11 of 42 (permalink) Old 01-04-2017, 06:27 PM
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Mine was gone when I got the bike( upper valve cover chain guide rubber piece) my dealer had one shopped in so kawasaki still has them as of 2016.

I just pushed mine on to the two posts real hard with my thumb till it bottomed out to the valve cover.

I asked this same question when I installed mine and I got anything from glue/epoxy to just push it on there.

The manual doesn't say anything about sealants or glues so I just pushed it on.

Year later after starts and running the engine, it's still there. Soooooo.....in theory you could just put it on there, but if you wanted insurance, glue it.........
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post #12 of 42 (permalink) Old 01-10-2017, 04:48 PM Thread Starter
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Quote:
Originally Posted by ninjanut View Post
Looking great! Stroker? Over bored?
That's a secret :). Although looking at the pictures are are enough clues there ;)
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post #13 of 42 (permalink) Old 01-10-2017, 04:50 PM Thread Starter
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Quote:
Originally Posted by Richard the Rooster View Post
Mine was gone when I got the bike( upper valve cover chain guide rubber piece) my dealer had one shopped in so kawasaki still has them as of 2016.

I just pushed mine on to the two posts real hard with my thumb till it bottomed out to the valve cover.

I asked this same question when I installed mine and I got anything from glue/epoxy to just push it on there.

The manual doesn't say anything about sealants or glues so I just pushed it on.

Year later after starts and running the engine, it's still there. Soooooo.....in theory you could just put it on there, but if you wanted insurance, glue it.........
Thanks Richard. I think I will dab a smear of araldite underneath just to be sure. Should take the heat well.

I am hoping the only reason the break is because the bikes are old and the rubber fatigues. Hopefully a new one will last a lot longer.
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post #14 of 42 (permalink) Old 01-10-2017, 04:52 PM Thread Starter
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Shimmed and dialled the cams. Getting close to completion as that is the last of the big jobs done now.







Sprayed up the head cover in a contrasting colour to the black. Looks like it will go faster now of course.

This was a gloss paint which in hindsight I should have prepped the surface better. I just cleaned off all the corroded parts and sprayed over the top, but with it being gloss you see the lumps and bumps unlike the matt black which is less noticeable. Still, it looks much better than it did and I was never really indenting on getting a showroom finish on a coat of engine paint. Should look good when fitted on :)
OTDR likes this.

Last edited by ritchie-t; 01-10-2017 at 04:59 PM.
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post #15 of 42 (permalink) Old 01-10-2017, 05:09 PM
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What did you set your cam timing #s to, or is that a trade secret? If so I get it.

Good job man, enjoying the thread.
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post #16 of 42 (permalink) Old 01-14-2017, 05:24 AM Thread Starter
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Quote:
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What did you set your cam timing #s to, or is that a trade secret? If so I get it.

Good job man, enjoying the thread.
Thanks for the comments :)

No big secret really on the cam timing as it is subject to change. The cams are very similar profile and lift to kit cams so I went with the kit setting of IN 103 Deg ATDC and EX 105 Deg BTDC. Seems like a logical place to start as I have no specs to work from on these cams and the clearance appears fine. I will have to see how it runs and it may need some further adjusting.
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post #17 of 42 (permalink) Old 01-14-2017, 05:33 AM Thread Starter
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Few more progress pics. Go faster sticker applied to get the lap times down of course!

I only need to get the sump on and clutch in now. All being well I should have this running tomorrow. I will be running it in using a leakdown tester to measure progress.
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post #18 of 42 (permalink) Old 01-14-2017, 05:50 AM
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Fire that thing up.
Take video of course


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post #19 of 42 (permalink) Old 01-14-2017, 01:02 PM
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Great progress.....you must be anxious to hear it come to life!!
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post #20 of 42 (permalink) Old 01-14-2017, 02:21 PM Thread Starter
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Quote:
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Great progress.....you must be anxious to hear it come to life!!
I must admit I am excited but also a bit nervous after the last one I built broke a conrod!

My fault, I knew it did not sound right and tried to understand what the noises were by running the engine and listening when instead I should have just turned it off right away and took it apart.
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