[90zxr750]

ok i bought the bike in boxes, had the motor reasembled and i mouonted it on the frame. i have a few more things to do, (learning as i go never done a bike before only cars) and im hoping you guys can help me out with some of the things i am confused about... the throttle cables and clutch stuff is all i have left pretty much... for now these have to do with the cooling system.....

ok what is the bottom hose used for? does it go to the nipple in the second picture i put up? if not what goes on each (the bottom hose and the nipple in the second pic...)

ok.. in this one it is a top view on the radiator cap that i installed and when i turn the handlebars to the right and back the part of the fork hits the connection point of the radiator cap and the gauge cluster...(the bolts for the cluster and all the cooling stuff is NOT tightened yet so does that loosnes cause the touching cause the clerence is close usually or am i missing something?..

ok lastly what is this hose lol...

sorry in advance for the long post.. i have been putting this project off and i am really trying to get it done for spring .. i will keep this post going with any other questions i will have so i dont crap up the forum... any help would be great guys thanks!!!

 

[blackedout7r]

go to bike bandit type in your model and look at the cooling section should show you where everything goes and what it looks like a service manual is alway a good idea

 

[2fat2fly]

ok i bought the bike in boxes, had the motor reasembled and i mouonted it on the frame. i have a few more things to do, (learning as i go never done a bike before only cars) and im hoping you guys can help me out with some of the things i am confused about... the throttle cables and clutch stuff is all i have left pretty much... for now these have to do with the cooling system.....

ok what is the bottom hose used for? does it go to the nipple in the second picture i put up? if not what goes on each (the bottom hose and the nipple in the second pic...)

ok.. in this one it is a top view on the radiator cap that i installed and when i turn the handlebars to the right and back the part of the fork hits the connection point of the radiator cap and the gauge cluster...(the bolts for the cluster and all the cooling stuff is NOT tightened yet so does that loosnes cause the touching cause the clerence is close usually or am i missing something?..

ok lastly what is this hose lol...

sorry in advance for the long post.. i have been putting this project off and i am really trying to get it done for spring .. i will keep this post going with any other questions i will have so i dont crap up the forum... any help would be great guys thanks!!!

The last hose looks like your crank case breather hose but not 100% positive.

The first mystery hose winds down and across the top of your exhaust and then over to the connection you show in the second photo.There are steel oring brackets above the exhaust at the head.The hose goes through them.If you let it just hang it will melt on the header.Tighten all bolts for the rad cap area and guages.Then adjust as necessary to get clearance.Everything is tight in that area.If you have any questions call me.I'll help all I can.

 

[Hammerhead]

Most good shop manuals have hose-routing and connection diagrams. If you are rebuilding a basketcase without one, you'e a braver man than I.

 

[90zxr750]

thank you that helped alot, i figured the clearence would be tight,

the only part left i will have trouble with is the clutch cable and the pedal shifter thing other than that its pretty much ready to go... i am playing with it tomorrow so between that and my manual i should be able to get it..

 

[90zxr750]

another question

can someone explain where the clutch cable connects to, the service manual does not show where it goes. which is odd. i can add a picture of the cable if neccessary, im going to go back out and tinker with the bike but come back in to check the forum if i cant figure it out lol

 

[2fat2fly]

can someone explain where the clutch cable connects to, the service manual does not show where it goes. which is odd. i can add a picture of the cable if neccessary, im going to go back out and tinker with the bike but come back in to check the forum if i cant figure it out lol

Your clutch is hydraulic.The hose goes from the left handlebar dowb to the left side of the engine.The Clutch actuator bolts to the front sprocket cover.Take a picture of the offending cable and post it.I'm guessing it's the choke cable.

 

[90zxr750]

Your clutch is hydraulic.The hose goes from the left handlebar dowb to the left side of the engine.The Clutch actuator bolts to the front sprocket cover.Take a picture of the offending cable and post it.I'm guessing it's the choke cable.

yeah i figured out the clutch thing except the fitment on the shifter link, which pic is correct pic 1, or pic 2?

pic 1)

pic 2)

and this is that cable

 

[Hammerhead]

If you have a cable clutch, there should be an actuator arm somewhere near the top of the clutch cover on the right side of the motor. Placement of the gearshift arm will depend on the pattern you like-either 1-down or 1-up. It could probably go on either way if there's no interference. Looks like the first pic is the stock (1-down) setting. Or not.

 

[2fat2fly]

I think picture 1 is the one.After bolting it together see which way it shifts.It should be 1 down and 5 up.If it's not the you're backwards.The choke cable goes to the top of the carbs.

 

[90zxr750]

thanks man that helped alot....

ok so basically the throttle cables is ALL thats holding me back, something is wrong and i cannot see what, i even took the throtttle apart at the handle bars its like the cables dont move freely they get messed up and stick... after that there pretty much is nothig left im frustrated its always something simpl that causes problems in the end

EDIT, i got the throttle issue fixed.

 

[2fat2fly]

thanks man that helped alot....

ok so basically the throttle cables is ALL thats holding me back, something is wrong and i cannot see what, i even took the throtttle apart at the handle bars its like the cables dont move freely they get messed up and stick... after that there pretty much is nothig left im frustrated its always something simpl that causes problems in the end

EDIT, i got the throttle issue fixed.

Glad to hear you have it all sorted out.I'm looking forward to hearing it run and seeing it in person.Don't forget to lube all your cables.

 

[90zxr750]

Glad to hear you have it all sorted out.I'm looking forward to hearing it run and seeing it in person.Don't forget to lube all your cables.

yeah i know i really want to be finished so i can just await spring... now is there something i should do before or the first time i turn it on?

 

[2fat2fly]

is there something i should do before or the first time i turn it on?

When you first start it,let it warm up.Cold weather and cold parts aren't a good mix.Keep the RPM's below 2500 initially.I'd like you to keep it at or near idle until you know you have oil pressure and a little heat in the engine.Have you cleaned the carbs?Even if you have you might want to go through them again to make sure they're clean.To make sure you're clear on everything,call Steve before you start it the first time to make sure there is nothing else he wants you to do.This way you and your engine builder are on the same page.

 

[2fat2fly]

Have your battery fully charged.It makes a difference when trying to start a new engine.It might not fire right off and you don't want to run the battery down.

 

[90zxr750]

Have your battery fully charged.It makes a difference when trying to start a new engine.It might not fire right off and you don't want to run the battery down.

ok will do thank you, yeah the battery is dead oi will have to charge it

 

[90zxr750]

final question

does the little modual that hangs down from the gas tank that has the little switch on it for "reserve" "off" and "on" just sit on top of the carbs? or does it lay somewhere accessable??

and can you explain the route of the gas lines? there is two coming from the bike, two hanging off the gas tank with that little modual at the end and then a thin one that goes from either side of the head area and comes together as one, ... as this is the only thing left to do ! i hope i can understand it soon so i can get it running tonight....
EDIT... GGRRRR i am having trouble with the stupidest thing right now, do you have to remove the drive sproket thing to get the chain on? and im having issues finding places for the midsection wiring by the batter (i have wires i dont know what connect to) its always something small in the end that holds up the process

thanks for all the help this was definately a learning process for me but i enjoyed it..

 

[90zxr750]

Wtf

i have juice flowing through it, (gauges come on and what not) but i cant get it to crank!!!

is the starter relay hard to find? and what else goes goes into that relay?
cause i dont hear plugs trying to fire either its dead silence.... or do the plugs fir with the starter motor?

either way im annoyed now.....

 

[motocon]

To find the relay, follow the pwr wire from the starter itself to the relay.The relay is round and should have a red cap on it.
Check your main fuse.It should be in the cap on your starter relay. The cap comes off the top of the relay and the fuse is inside, 30A I think....
Your bike may also have an inline fuse running from the battery, look for a small cylindrical case with a pwr wire running through it.

Make sure the kill switch (main) is in the proper position set to "RUN"....

Not sure exactly what you mean by hearing the plugs fire.....
First get it to crank over, you won't actually hear the plugs fire but can check for spark when it cranks over!

Keep the faith, Ive been there and it's worth the patience......

 

[90zxr750]

thanks for the reply... the problem is i know where the relay is and fuses i just cant get it to crank when i hit the button and yes the kill swith is on on lol... any ideas? how do i "jump" the starter?

To find the relay, follow the pwr wire from the starter itself to the relay.The relay is round and should have a red cap on it.
Check your main fuse.It should be in the cap on your starter relay. The cap comes off the top of the relay and the fuse is inside, 30A I think....
Your bike may also have an inline fuse running from the battery, look for a small cylindrical case with a pwr wire running through it.

Make sure the kill switch (main) is in the proper position set to "RUN"....

Not sure exactly what you mean by hearing the plugs fire.....
First get it to crank over, you won't actually hear the plugs fire but can check for spark when it cranks over!

Keep the faith, Ive been there and it's worth the patience......