93 ZXR750 M rebuild - ZX Forums
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post #1 of 40 (permalink) Old 02-26-2015, 02:19 AM Thread Starter
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93 ZXR750 M rebuild

Hi guys,

It has been some time since I last posted about my M1. Just to jog your memories, this is what I am starting with:







Nothing much has happened in the last 6 months apart from slowly stripping the parts from the partially reassembled roller. While it looks ok, only the outsides of the frame rails have been cleaned and stripped. The inside and all the swing-arm pivot casting area are all covered with flaky, half stripped paint, or layers of chain oil gunk.

This has all changed now, as the space that the M is taking is needed for this:



This morning was spent in the shed stripping everything off the chassis - harness, some plastics, instruments etc.

All went pretty smoothly until I got to the side-stand bolts. One was tight, the other started to round off. Damn. Secondly, the swing-arm pivot. What's the trick to this? I've looked at the manual and it looks like you just take off the nut on the lhs, and it should come out? Mine is firm. I can rotate it with a socket, but it won't slide out. I've put some penetrating oil and given the end a couple of sharp taps with a small hammer, but it's not budging. I'm thinking that given the way the rest of the bike has been assembled, there hasn't been the faintest hint of grease on anything, it has probably frozen to either the bearings, spacers, or both.

You guys got any hints on how to how to get this thing out?

Apart from that, it'll be off to the tool shop to get a 36mm socket for the stem nut, then forks out, then off the the blaster.

Last edited by SC00BS; 07-21-2017 at 04:32 PM. Reason: replace dead photobucket links
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post #2 of 40 (permalink) Old 02-26-2015, 03:33 PM
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How is the bike standing right now?

I hope you're not trying to remove the swingarm pivot with the bike on stands?

I had to rig up a ladder and straps and support the back end via the subframe to be able to work the swingarm bolt in and out.

1991 Kawasaki ZX-7R / Russell replica (in progress)
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post #3 of 40 (permalink) Old 02-27-2015, 07:25 PM Thread Starter
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Just a frame and swingarm. Not on stands, & with the shock and linkages removed.

Managed to get the left side swingarm pivot plate off. The collar underneath that in the seal was a bit rusty looking when I removed it, so I'm guessing the main spacer will be similar. At least I can get penetrating oil directly to the pivot now. I'll give it a good soak and see how it goes tomorrow.

Oh, and the side-stand bolt is now out.
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post #4 of 40 (permalink) Old 03-01-2015, 07:13 AM
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You not got an alloy tank in them boxes ??
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post #5 of 40 (permalink) Old 03-01-2015, 01:23 PM Thread Starter
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Yep, it's painted blue and on the bike. No spare if that's what you were going to ask.

Pivot bolt is still stuck fast. It doesn't sound like it's even loose, just like it is banging on the inside of the frame (ie the end of the swingarm).

Is there anyone with experience with an M that can confirm that there's nothing special or tricky about removing these - no hidden bolts or clamps?

Cheers
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post #6 of 40 (permalink) Old 03-01-2015, 02:24 PM
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What bolt are you referring to

ZX7RR WSB Yanagawa

ZX7RR Muzzy Race Raptor
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post #7 of 40 (permalink) Old 03-02-2015, 01:56 AM Thread Starter
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The swingarm pivot shaft. I have removed both the nut and the adjustable pivot plate (with the 4 cap screws) from the lhs, but it won't budge. The rhs end of the swingarm is hard up against the inside of the frame. I've given the end of the shaft a few sharp taps with a hammer, but it just feels and sounds like there is something that is preventing it sliding out.
I've looked in the manual and the parts list and can't see anything obvious. I'm at a loss as to what might be preventing it coming out.
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post #8 of 40 (permalink) Old 03-02-2015, 02:34 AM
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Quote:
Originally Posted by SC00BS View Post
The swingarm pivot shaft. I have removed both the nut and the adjustable pivot plate (with the 4 cap screws) from the lhs, but it won't budge. The rhs end of the swingarm is hard up against the inside of the frame. I've given the end of the shaft a few sharp taps with a hammer, but it just feels and sounds like there is something that is preventing it sliding out.
I've looked in the manual and the parts list and can't see anything obvious. I'm at a loss as to what might be preventing it coming out.
The swing arm has a steel sleeve in the middle (between the right and left side bearings) if it hasn't been lubed properly over the years then it may be seized to the pivot bolt. Start spraying some penetrant oil around the bolt and keep repeating this for a few days to try and help free it up. If nothing else works then you may have to resort to a hammer and block of wood to pound it out.

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Last edited by 2fat2fly; 03-02-2015 at 05:34 AM.
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post #9 of 40 (permalink) Old 03-02-2015, 04:37 AM
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This has worked..evaluate damage potential ...cover area around pivot shaft ends / frame with alloy foil and put several layers at immediate area of heat....fold alloy foil to make a cone...this cone you fabricate is to help you direct the flame from the heat gun into the hollow of the pivot shaft...apply heat to both sides of pivot shaft inturn ...warm the shaft up slowly...say 7 to 10 secs of heat/blue flame....listen out for heat expansion..ticking...allow to cool and repeat a couple of times before hammer/wood shaft.Evaluate RISK before turning on heat gun...alloy foil is cheap and can prevent damage once put in place.
Quote:
Originally Posted by 2fat2fly View Post
The swing arm has a steel sleeve in the middle (between the right and left side bearings) if it hasn't been lubed properly over the years then it may be seized to the pivot bolt. Start spraying some penetrant oil around the bolt and keep repeeating this for a few days to try and help free it up. If nothing else works then you may have to resort to a hammer and block of wood to pound it out.
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post #10 of 40 (permalink) Old 03-02-2015, 04:50 AM
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Quote:
Originally Posted by SC00BS View Post
Hi guys,

It has been some time since I last posted about my M1. Just to jog your memories, this is what I am starting with:





Nothing much has happened in the last 6 months apart from slowly stripping the parts from the partially reassembled roller. While it looks ok, only the outsides of the frame rails have been cleaned and stripped. The inside and all the swing-arm pivot casting area are all covered with flaky, half stripped paint, or layers of chain oil gunk.

This has all changed now, as the space that the M is taking is needed for this:



This morning was spent in the shed stripping everything off the chassis - harness, some plastics, instruments etc.

All went pretty smoothly until I got to the side-stand bolts. One was tight, the other started to round off. Damn. Secondly, the swing-arm pivot. What's the trick to this? I've looked at the manual and it looks like you just take off the nut on the lhs, and it should come out? Mine is firm. I can rotate it with a socket, but it won't slide out. I've put some penetrating oil and given the end a couple of sharp taps with a small hammer, but it's not budging. I'm thinking that given the way the rest of the bike has been assembled, there hasn't been the faintest hint of grease on anything, it has probably frozen to either the bearings, spacers, or both.

You guys got any hints on how to how to get this thing out?

Apart from that, it'll be off to the tool shop to get a 36mm socket for the stem nut, then forks out, then off the the blaster.
SIDE STAND BOLTS Had similar problem on my p4 only one bolt sheered off because it had seized into the alloy frame..There was enough thread for me to put a nut onto...but even welding the nut onto the bolt it still wouldnt budge ..a pretty solid weld would break first..tried this 4/5 times..in the end i ground off the exposed bolt with a angle grinder then drilled and re tapped a thread..all went well good result...made sure to use copper slip grease on putting new fixings in.
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post #11 of 40 (permalink) Old 03-03-2015, 02:47 PM Thread Starter
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Thanks guys. I suspected that the steel space was the issue, but wanted to confirm that there wasn't something else preventing it's removal that I wasn't aware of.

It looks like the heat/torch is the way to go. I'll keep you posted.
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post #12 of 40 (permalink) Old 03-10-2015, 06:02 PM
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G'day scoobs. I was only thinking about your bike the other day and wondering how it was coming along. I spoke to the previous owner on the phone at the time and was considering buying it when it was on eBay. Thanks for the update
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post #13 of 40 (permalink) Old 03-16-2015, 03:10 AM Thread Starter
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It's free - but don't ask. Now have the frame separate, adjustable swingarm blocks out. Now to pull the steering head bearings out and give it a clean.

What do you guys think gives the best finish - paint or powder coat?

@zxrmad, yeah, I had spoken to the guy a few times, mainly about the '95 L3 he had as well. In the end he came down a fair bit from what he was asking initially. Just as well considering the condition of some parts. What stopped you from grabbing it?
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post #14 of 40 (permalink) Old 03-16-2015, 03:01 PM
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Quote:
Originally Posted by SC00BS View Post
It's free - but don't ask. Now have the frame separate, adjustable swingarm blocks out. Now to pull the steering head bearings out and give it a clean.

What do you guys think gives the best finish - paint or powder coat?

@zxrmad, yeah, I had spoken to the guy a few times, mainly about the '95 L3 he had as well. In the end he came down a fair bit from what he was asking initially. Just as well considering the condition of some parts. What stopped you from grabbing it?
The bloke wasn't very helpful on the phone and didn't seem to know a lot about the bike, also wasn't interested in negotiating much on the price at the time. Hope you got a good deal. Glad you're making some progress with it, not many M's on the road in Aus.

Frame and swing arm were originally painted from factory, so I'd re-paint if it were me.
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post #15 of 40 (permalink) Old 07-07-2017, 06:30 PM Thread Starter
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Wow. Can't believe two years has slipped by......

Being out of work for a while certainly slowed things down, but that's all sorted now. I had been chipping away at a lot of little things, a few powder coated stays, a batch of re-plated fasteners & brackets, a few new bearings & seals etc, but getting the frame repainted has spurred things along!

Hmmmmm. Images not working......

http://imgur.com/IxpXc0K
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Last edited by SC00BS; 07-08-2017 at 08:34 PM.
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post #16 of 40 (permalink) Old 07-08-2017, 11:05 PM Thread Starter
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post #17 of 40 (permalink) Old 07-09-2017, 01:35 PM
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Quote:
Originally Posted by SC00BS View Post
Here:







Did they also paint where the bearing are going to be?
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post #18 of 40 (permalink) Old 07-09-2017, 05:36 PM Thread Starter
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Thanks. I'm using a new image host since photobucket is no longer playing nicely......
What code do I have to add to get the files to display as images? The urls from the hosting site didn't work when I tried them.
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post #19 of 40 (permalink) Old 07-09-2017, 11:40 PM
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Thanks. I'm using a new image host since photobucket is no longer playing nicely......
What code do I have to add to get the files to display as images? The urls from the hosting site didn't work when I tried them.
Open the image, rightclick and select 'copy image address', use that link in your posts...

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post #20 of 40 (permalink) Old 07-11-2017, 03:52 AM
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Nice looking parts.
Sweet subframe!


Sent from my new fangled morse code machine.

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1998 ZX7R - Endurance body, named Frenchie
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