Author Topic: Terry's Kawasaki ZZR1100 "Bring it back to life" project. (Read 74220 times)

Terry in Australia · « **Reply #325 on:** September 06, 2018, 10:40:49 pm »

Thanks Ken, I'm actually feeling pretty good, I told the wife that I could go back to work next week (I'm not due back 'til the 17th) but she told me that no I couldn't, so we agreed that I could be allowed to do some "light" (no heavy lifting) bike stuff next week instead because sitting watching TV every day is fcuking boring!

I've been meaning to start a separate thread for my Z1000 dragbike - street beast build, so I've kicked one off here, as it's next cab off the rank once I get the ZZR1100 engine back together next week. Woohoo!

http://forums.sohc4.net/index.php/topic,174026.msg2025018.html#msg2025018

BobbyR · « **Reply #326 on:** September 07, 2018, 06:19:18 am »

I am sure this new build will be up to your usual standards. Glad you are up and around. Don't push it and hurt yourself.

Terry in Australia · « **Reply #327 on:** September 11, 2018, 04:05:22 am »

Thanks Bobby! Yep the new build is getting closer, as is the collapse of my finances, but WTF, when I was waiting for the "dye test" (the worst thing I've ever swallowed, ever) in the Radiology section at Hospital last week I had a chat with an ex-maths teacher called Graham who had terminal lung cancer and I couldn't help but think that there are worse things than being slightly broke.

Anyway, today was the best day on sick leave ever! Tim, my youngest son drove me over to Bunnings (big box hardware) for a wander around, I didn't really want to buy anything, I was just going stir crazy and needed to get out of the house. On our return I wandered out the back into sunny warm weather, and decided to start putting the ol' ZZR engine back together. I torqued the head down, (and twisted my guts in the process) 39 foot pounds? It's no wonder CB750 heads weep oil and ZZR1100 heads don't!

I torqued the head down and was quite proud of myself, before I realised that I'd left the front cam chain guide out, AAARRRGGGGGHHHH! It's just a big chunk of moulded rubber so I spent 10 minutes trying to force it in from several angles, then 5 minutes undoing all the head bolts, lifting the head, dropping the tensioner in place, and torqueing it back down. D-uh!

Similarly I reckon I had the cam timing absolutely spot on before I tightened the cam saddles down, and by the time I installed the tensioner it looked like the inlet cam was a tad out, so I'll take another look at that tomorrow, I don't want to jump in and undo everything I did today because it looks like it's closer to half a tooth out than a full tooth, and the exhaust cam is spot on, so it might be OK.

Anyhoo, it was a great day, and a great change from sitting on my duff watching the idiot box. I was really pissed off though, that after scraping off the remains of the old cam chain tensioner gasket I discovered that there was not another one in the $200 (USD) Athena gasket set, but I managed my rage well, and broke out the black silicon.......

The weather tomorrow is not gonna be as good, but that's OK, as long as it's not raining on me, I'll be out there, getting it done.......

ZZR Tuesday by terry prendergast, on Flickr

ZZR Tuesday 1 by terry prendergast, on Flickr

PeWe · « **Reply #328 on:** September 11, 2018, 06:48:23 am »

You have used assembly lube this time? You used other stuff as STP before, right?

BobbyR · « **Reply #329 on:** September 11, 2018, 02:49:18 pm »

Looking good Mate. Glad you had that chat with that fella. People forget what is important until it is too late and you can't indulge yourself. Don't overdo it Mate, heal up properly.

Terry in Australia · « **Reply #330 on:** September 12, 2018, 03:47:01 am »

Thanks guys! Per, I used "Red Line" assembly lube. I've never used an assembly lube before, (well, I did on the Megacycle cam I had on my 836, but only because it came with it) I know bike mechanics who laugh at the thought of using it as they've always just used engine oil, and so have I, with no issues at all.

The only reason I'm using this stuff is once again, because it came with the 1250cc kit I bought for my Sportster, and as I knew this engine wouldn't be going together quickly I didn't want to leave the crank bearings etc without any lube when I knew it was going to sit for awhile.

Today was sunny, but cold. Well it might be just me because according to my iphone it was 18 deg C (64 deg F) but I was freezing! Don't know why, I had a warm top on, I hope I'm not coming down with something? Anyhoo, the show must go on. I re-checked the cam timing and I was 1 tooth out, but surprisingly it was easier to fix than on a CB750! Remove the cam chain tensioner, unbolt the cam saddles for just the inlet cam, pull the chain one way and the cam the other, rotate the cam one tooth on the sprocket, and bolt it all back together, nice!

I spent more time trying to find the little 5mm screws that secure the ignition sender. When I stripped the engine I did it in stages and had little containers of screws for each stage. I ratted thru al the containers and had just about given up when I found another container on the bench with my front sprocket in it, and those tiny screws underneath! Anyway, I installed the ignition, spent ages cleaning the old gasket off the cover, cleaning the cover itself, finding the container of cover screws, and installing the cover with it's new gasket. By then I decided that I'd had enough, packed up and came inside.

Tomorrow's supposed to be slightly warmer, so hopefully I'll be putting the final touches to it then. Cheers, Terry.

ZZR top end complete by terry prendergast, on Flickr

MoMo · « **Reply #331 on:** September 12, 2018, 05:30:14 am »

Probably feels colder because you have less body fat insulation. Just saying

Take it easy for awhile, hard to do with your make up. Take care...Larry

jgger · « **Reply #332 on:** September 12, 2018, 06:04:45 am »

Terry wears make up?

Egil · « **Reply #333 on:** September 12, 2018, 07:09:38 am »

Great reading

Terry in Australia · « **Reply #334 on:** September 12, 2018, 06:53:05 pm »

Thanks everyone, and welcome back Egil! You might be right Larry, my wife's told me that I've already lost my belly, so maybe that was why I was so cold yesterday. Being the hoarder that I am, my wardrobe is like "Doctor Who"s "Tardis", the further I go back into the wardrobe the further I go back in time, with clothes that I've forgotten about, which now fit me again.

I'm wearing a shirt that was just a tad too tight last time I wore it a couple of years ago, but now is nice and loose, and I found a jacket I bought 10 years ago that is a great fit now. We've been in this house for 17 years since I retired from the regular Army and that's about the time I started putting on the weight, so it's nice to work my way back in time, by the time I hit the back of the wardrobe I'll be a good looking Rooster!

I don't think that Larry thinks I wear make up Jgger, I think he means that "taking it easy" isn't in my DNA. Well, I do like to take it easy at work, but when the sun is shining out in my patio workshop, I like to get my hands dirty! Cheers, Terry.

jgger · « **Reply #335 on:** September 12, 2018, 07:08:32 pm »

Just funnin' ya Terry.

Sounds like the weight loss is going great for you, but as you dig back into the wardrobe history vault stop before you hit the leisure suit section please. That and pm Frank and get the scoop on suspenders, you don't want to go around looking like some gang banger rapping punk do you?

Terry in Australia · « **Reply #336 on:** September 12, 2018, 07:23:57 pm »

Ha ha, no leisure suits mate, I've always been a "Jeans and T shirts" guy, so fashion that never goes out of style! My folks did a few trips to the US back in the 90's to visit my sister who lived in CA for 20+ years, and each time they came back they'd bring me back Levis jeans and shirts, Jackets, boots etc (Canadian Wedding Suit?) so I'm working my way back to some "vintage" fashion, ha ha! I think I've got a couple of business suits back there that are still in style, so that might be a good thing too.

MoMo · « **Reply #337 on:** September 12, 2018, 09:40:47 pm »

Around here we call it a Canadian Tuxedo.........jeans, denim shirt and jeans jacket. But .............................there is nothing worse than a Canadian male swimming trunks

Terry in Australia · « **Reply #338 on:** September 13, 2018, 04:12:55 am »

Yeah that's right, Canadian Tux! Well another sunny cold (for me at least) day but I strode manfully out to the patio and did some more today, didn't get it finished as I had to spend a lot more time cleaning grease and crap off everything, find the right screws again, find the correct gaskets, clean the old gaskets off etc, but hey, won't be long now!

The sump pan is soaking in degreaser because it had a muddy black ooze in the bottom of it, full of metal chips, and what looks like a circlip, in two pieces? I hope it's from when the PO blew second gear, I gave all the gears a cursory glance and didn't notice anything untoward, but I think tomorrow I'll flip it over and take a closer look at the gearbox, just in case. OK, I'm off to bed, like a dick I drank a 400 ml "smoothie" tonight, it was delicious, but too much volume for the old bread basket right now, so I'll probably be suffering all night. Oh well......

ZZR engine closer by terry prendergast, on Flickr

Terry and Leo 13 Sep 2018 by terry prendergast, on Flickr

MoMo · « **Reply #339 on:** September 13, 2018, 04:37:47 am »

Leo might stop snuggling once you get down to six pack abs Terry, you know all that soft tummy cushion will be gone

RAFster122s · « **Reply #340 on:** September 13, 2018, 05:30:09 am »

Glad you are doing well Terry and are able to do quite a bit, even if it is not following DR's orders.

Just don't overdo it and hurt your self.

David

ekpent · « **Reply #341 on:** September 13, 2018, 05:48:27 am »

One happy looking contented cat !!

BPellerine · « **Reply #342 on:** September 13, 2018, 06:03:46 pm »

Quote from: Terry in Australia on September 12, 2018, 07:23:57 pm

Ha ha, no leisure suits mate, I've always been a "Jeans and T shirts" guy, so fashion that never goes out of style! My folks did a few trips to the US back in the 90's to visit my sister who lived in CA for 20+ years, and each time they came back they'd bring me back Levis jeans and shirts, Jackets, boots etc (Canadian Wedding Suit?) so I'm working my way back to some "vintage" fashion, ha ha! I think I've got a couple of business suits back there that are still in style, so that might be a good thing too.

make that a redneck wedding suit,us canadians know how to dress,haha.you get canadian suits in the us?haha,bill

Terry in Australia · « **Reply #343 on:** September 13, 2018, 06:57:40 pm »

Oops, sorry Bill! Anyway, I'm looking forwards to fitting back into my "Tux" mate, it's been close to 20 years since I last wore it! According to my scales I've now lost 42 pounds so I'm pretty happy right now, even if I still feel like I've been kicked in the guts.

Sadly I have to go back to work on Monday which I'm really not looking forward to, I was bored out of my brain until a couple of days ago when I was allowed outside to work on the ZZR engine again, and ever since it's been great, just 3 hours or so each day, but that's enough to maintain my interest.

Anyway, it's lunchtime, so I suppose I better find something disgusting to sip, (one month on a liquid diet anniversary today, boohoo) then I'll head outside into the sun. Cheers, Terry.

RAFster122s · « **Reply #344 on:** September 13, 2018, 08:54:24 pm »

Enjoy the sun Terry, it is good you did the surgery when it was spring, that way the exercise program outside will not be as difficult to keep going in summer if you stick with it. Working in AC won't make it easy as you acclimate to the cool temp and not the outside weather and heat.

That is great you have lost so much in a month! I am sure it makes moving around and feeling better about being lighter. The exercise helps with the stretched skin too from the weight gain to a point...

David

cb750k7 · « **Reply #345 on:** September 13, 2018, 09:33:44 pm »

Hi Terry
Did you try this product??

Get well soon and keep on your kicking :-)

Terry in Australia · « **Reply #346 on:** September 15, 2018, 07:35:59 pm »

G'Day Jona, how are you mate? Well I don't use any sealant usually, if the gaskets are good quality and the surfaces have no damage, I don't think it's necessary? I only used the black silicon on the top and bottom engine case halves (because there's no gaskets) and the missing cam chain tensioner gasket. I still may make a proper gasket for the tensioner, the last thing I want is an oil leak once the engine's back in the frame.

Friday was another great day, sun shining, birds singing etc, so I headed out to do some more wrenching. I didn't get all that much done, once again due to more gasket cleaning on the engine side, and the cover. Inside the cover there is a steel retainer plate held in by 4 screws that goes over a thick rubber sheet that (I presume) dampens any clutch noise. There's also an oil line that directs oil from the engine to the cover.

Anyway, considering all of the metal particles that I found in the sum pan, I thought it wise to pull everything apart and give it a good degreasing, and was rewarded with a tiny amount of metal in the bottom of my plastic tub. It's starting to get serious now, I need to clean the sump pan, all the oil lines, the pump and even the oil cooler to make sure that nothing is left to wreak havoc in my freshly rebuilt engine.

ZZR engine almost done by terry prendergast, on Flickr

The weather this weekend has been foul, back to winter-like conditions, so the bike play will have to wait. That's OK, I need to throw half a can of Seafoam into my magnificent Ford Exploder and see if that helps the rear cam chain tensioner's function. When I changed the oil I added oil thickener (Moreys) not realising that it might be too thick to get into the oil ports in the automatic cam chain tensioner. The Seafoam worked a treat on the Hyundai Excel's sticky lifters, so who knows? It'll give me a chance to drive the old beast again at least, I don't think I've driven it in maybe 2 years? Should be good fun!

Terry's Exploder 2 by terry prendergast, on Flickr

RAFster122s · « **Reply #347 on:** September 16, 2018, 11:18:38 pm »

SeaFoam actually works well for that purpose Terry. Amazing it is not a bit of hype given so much is these days. Snake oil everywhere on the shelves of the auto parts stores. PT Barnum expression applies.

David

BobbyR · « **Reply #348 on:** September 17, 2018, 11:29:04 am »

Nice looking Explorer. I guess they do not salt the roads in the winter.

Terry in Australia · « **Reply #349 on:** September 17, 2018, 01:23:02 pm »

Thanks guys! I found a supplier of Seafoam here in Oz, so I ordered a couple more bottles, so far I've had excellent success with it, and another great line of products under the "Pro-Ma" brand, that actually do what they say they will. I think I'll add a little Seafoam to the big Kawasaki's oil when I'm done putting it back together to flush any metal into the sump.

Bobby, no rust in the old Ford at all, it's in excellent condition for 20 years old, the OP paid $58,000 for it new, and I (3rd owner) paid the princely sum of $1600 for it in 2015? Not a good investment for her, but I'm very happy. Yeah, the only salt here is on our chips. (Fries)

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Author Topic: Terry's Kawasaki ZZR1100 "Bring it back to life" project. (Read 74220 times)