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Project Kawasaki ZXR400

Discussion in 'Other Projects - Other Bikes (non 250's)' started by kiffsta, May 2, 2017.

  1. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Hey All

    Here is my latest project. its a 1994 ZXR400 which I spotted last night on Gumtree, I paid full asking price from the seller and headed down to Ormeau at lunch to collect it.

    IMG_0362.JPG

    20170501_133533_HDR.jpg

    It was partially disassembled so I figured lets pull the carbs off for a look, what I found was pretty scary.

    IMG_0369.JPG
    IMG_0370.JPG


    I think these would have to be the worst set of carbs that I have worked on, all the slides were jammed solid, they are now fully apart and will reassemble them tomorrow and see if I can get her started. If she has a strong motor then I have some serious plans for it and a 6 month timeframe to get her sorted, hopefully I can have it ready for our ride later in the year.

    This one is interesting as it has the water cooling on the carb bowls.

    The seller of the bike is keen to see how she comes up so I have sent him the link to this thread.

    Kiff
     
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    Last edited: May 2, 2017
  2. Phil

    Phil Well-Known Member Premium Member Contributing Member

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    Looks like a job for "threebond"
    There is a serious amount of gunk in those carb.
    Bike looks ok....love to hear that engine run....here's hoping !!

    Sent from my SM-G900I using Tapatalk
     
  3. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Good job for your new blaster. :D
     
  4. Grasshopper

    Grasshopper Well-Known Member Premium Member Dirty Wheel Club

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    Nice one... look forward to watching the progress of this project :thumb_ups:
     
  5. aarondugs

    aarondugs Active Member

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    nice find mate, always keep my eyes out for these, lots and lots of parts available for them aswell, cant wait to see the progress
     
  6. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club

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    Nice, I want one when I get my fulls... hit me up if you still have it then (January) :)
     
  7. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Look forward to seeing this project.
    That would be water heating on the float bowls, but not much snow though in sunny Queensland. I would be ditching that option Kiffsta.
     
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  8. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    Bad news guys she is seized, when I tried to fire it up this morning it went "clunk", I pulled the starter out and bench tested it and it was fine. I dropped the oil and there was a heap of water in there, which is probably why it has Seized. I poured a cap ful of oil down each pot and let it sit for a few hours Later on today I removed the stator cover and attached a socket to the stator bolt and gave it a gentle push each way, she freed up and I gently rotated the engine until she spun freely.

    I have a feeling I am going to have to strip it down and see what going on inside.

    Such a shame, I have bought so many bikes in much more neglected states that were not seized like this one
     
  9. Frankster

    Frankster See the world before you leave it. Staff Member Premium Member Ride and Events Crew

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    Sorry to hear that Chris. Pull the head off and have a look. Water and bores/pistons are mortal enemies, but you might have caught it before serious damage has occurred. Do you know which model it is? I think they come in L, M & maybe a few other variants.
     
  10. Joker

    Joker CLUB250 Staff Member Premium Member Ride and Events Crew Contributing Member

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    free spinnin is good enough for a push start. She'll be right mate :D
     
  11. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club

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    Beg/borrow/buy/steal an automotive inspection camera... I got one from Jaycar for just this type of situation. Have a look down the bores without pulling the bike to bits :thumb_ups:
     
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  12. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    I have one , will have a look tomorrow
     
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  13. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    IMG_0729.JPG IMG_0730.JPG Frankster is helping me out this week, we pulled the engine out , good comp on 3 and 4 , 1 and 2 is a different story , will know more on Monday when we pull it down
     
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  14. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    the head came off easily enough, nothing to untoward there at first glance

    IMG_0746.JPG

    next the barrels came off, @Frankster called it pretty quick, cylinders 1 and 2 rings were closed up as compared to 3 and 4 which were loose.

    IMG_0748.JPG
    IMG_0749.JPG

    next job is pulling the valves out and cleaning up the head, I will order some new rings, new head and base gasket and a cam chain. The barrels look quite good, wills end them off to a mate of mine who is a bike mechanic and get them honed

    IMG_0753.JPG
    Wet blasted a valve, it took all the crud off
    IMG_0754.JPG
     
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  15. ruckusman

    ruckusman Well-Known Member Premium Member

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    I've had anecdotal opinions from two mechanics that ethanol blended fuels cause excess carbon buildup in ring lands and the vow never to use ethanol blends.

    One said that the ring lands were so badly clogged on one engine that the accumulated blowby on the pistons meant he had to hit them out with a piece of timber and a mallet

    Just opinions I know, but I'd love to know the truth of it
     
  16. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    IMG_0761.JPG And game set match , moisture wins

    Anyone want zxr400 parts ?
     
  17. Cbuzz

    Cbuzz Member Dirty Wheel Club

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    Is that a crack or rust ? Looks nasty wherever it is !
     
  18. kiffsta

    kiffsta Administrator Staff Member Dirty Wheel Club Contributing Member

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    the liner has rusted in 1 and 2 , I just cant justify the additional cost to bring her back, I'm sure I will find another :thumb_ups:
     
  19. Cbuzz

    Cbuzz Member Dirty Wheel Club

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    Dam that sux. Is it pitted or just surface rust ?

    Those 400's are hard to come by.
     
  20. Andych

    Andych Well-Known Member Premium Member Contributing Member

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    Screw it.... go Big Bore.... :)
     
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