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Tomfoolery
Member
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Posted: Thu Apr 17th, 2008 02:47 pm |
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Right, my ZZR has sat in my front garden for way too long. The weather's looking better, and now seems as good as any to start work on the beauty. Especially as my brother is now eyeing her jealously only 3 weeks after passing his CBT and buying a scooter.
First step - Putting her in the back garden:
  
For a glorious 15 minutes, I had my dream of working on her indoors. Bloody flatmates 
She's now positioned in the (south-facing) back garden, where I will start work on her.
Important things to do:
- Find out why the battery doesn't hold a charge/doesn't start
- Ascertain where oil leak is coming from and fix it
- Rectify top-end rattle (cam-chain?)
- Sort front end woes - new front tyre and change of fork oil sorted it
- New front discs - not needed
- New front tyre - Bridgestone BT014 fitted
- Change fork seals - from Wemoto.com
Not so important things to do:
- Fix Scottoiler
- Clean off all sticky-back plastic carbon fibre crap
- Paint swingarm
- Fix broken plastics (previous owner)
- Paint calipers
- Paint fork lowers
- Sort centrestand (hardly lifts the rear wheel off the ground)
- Stop left hand twistgrip from moving - Renthal grips fitted
- Fix heated grips - Renthals fitted
- Change PB sticker on right hand fairing
I hope to finish by the end of the Summer. Most of the work won't cost much at all, save for the discs, tyre(s) and parts, if needed, to sort the starting/charging problem.
I have a Haynes manual, the original workshop manuals, and some half-decent tools and a multimeter, wish I have no idea how to use.
The red items are things I have completed.
Wish me luck!
Last edited on Sun Aug 24th, 2008 12:37 am by Tomfoolery
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rossm
Member
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Posted: Thu Apr 17th, 2008 03:00 pm |
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Good luck
Ross
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fuelline
Member
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Posted: Thu Apr 17th, 2008 03:24 pm |
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Good Luck the Second
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Tomfoolery
Member
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Posted: Thu Apr 17th, 2008 03:49 pm |
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Thanks, guys. Any advice or encouragement is gratefully recieved.
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Gray01
Member
| Joined: | Thu Jun 14th, 2007 |
| Location: | Hazzard County |
| Posts: | 2245 |
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Posted: Thu Apr 17th, 2008 04:14 pm |
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Should be fairly simple to sort that out Fool...a man of your talents should have no trouble at all...
Oh...and luck is overated, just use skill
Get on it.
G.
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Tomfoolery
Member
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Posted: Thu Apr 17th, 2008 04:19 pm |
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Ta, lad. I will need help using my multimeter, though 
Removed the battery and put it on charge (massive thanks to Hoona6 for the charger!). Also drilled holes in the battery tray cos it was full of water.
It's all in the details...
Last edited on Thu Apr 17th, 2008 05:20 pm by Tomfoolery
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Gray01
Member
| Joined: | Thu Jun 14th, 2007 |
| Location: | Hazzard County |
| Posts: | 2245 |
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Posted: Thu Apr 17th, 2008 05:24 pm |
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Foolers, a PM to supermoto01 should see you right on the multimygodwhatdoesthatmeanmeter...
...he knows all about this elastic-trickery stuff...
...coz he is an elastictrician init
G
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Tomfoolery
Member
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Posted: Thu Apr 17th, 2008 05:29 pm |
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Thanks, dude. I will definitely be calling on him at some point soon! Once the battery's charged tomorrow, I'll be able to see what the bike does, so I can fix what it can't.
Sweet!
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kwakbiker-Z1000
Member
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Posted: Thu Apr 17th, 2008 07:04 pm |
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| Probably the regulator/rectifier for the battery if it starts off good but goes downhill quick. Enjoy the project
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SamB
Member
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Posted: Fri Apr 18th, 2008 10:16 am |
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Always love those ZZRs - a classic in my opinion.
Good luck with the project.
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mac d
Member
| Joined: | Mon Jan 8th, 2007 |
| Location: | Land Of OZ |
| Posts: | 1148 |
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Posted: Fri Apr 18th, 2008 01:26 pm |
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Good to see you getting it going again. A few points to check out:
The top end rattle (they all do that sir...) often seems to be the cam chain, as you suspect, the auto tensioners tend to stick. Pull it out, give it a good clean and once-over to check for damaged teeth, then give it a lube and chuck it back in and give it a light tap. Good time to check the valve clearances too.
For the charging issue make sure all the terminals in the charge circuit (mainly the 3x yellow wires) are in good nick then look at the regulator and make sure the resin on the back is not fried or cracked, then start going through the tests in the manual. Sounds obvious, but is there sufficient acid/water in the battery? If the reg is OK but the test are out check out the alternator windings to see if they looked cooked. As if it's not obvious yet, I've had all the above issues.
This is reminding me of all the jobs i should be doing to mine rather than cutting it up
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Mustard
Member
| Joined: | Mon Feb 12th, 2007 |
| Location: | Kingston, Australia |
| Posts: | 124 |
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Posted: Sat Apr 19th, 2008 08:34 am |
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| Hey Mac D where you been hanging out? Havent seen you on here for aaaaaages!
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mac d
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| Joined: | Mon Jan 8th, 2007 |
| Location: | Land Of OZ |
| Posts: | 1148 |
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Posted: Sun Apr 20th, 2008 01:30 pm |
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Hey Mark, I'm still around the place.
Not spending as much time on here these days, mainly just look through every few days to check for anything interesting rather than going straight in after turning the computer on. Consciously attempting to avoid getting caught in the General rants and cut down my online time!
That plus I've been away for 2 of the last three weeks: Bris Vegas for a while, then Sydney for a trade show.
Roughly painted the tail today, will put up some pics later (when I take them)
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deviant
Member
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Posted: Sun Apr 20th, 2008 04:49 pm |
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mac d wrote: ...as you suspect, the auto tensioners tend to stick. Pull it out, give it a good clean and once-over to check for damaged teeth, then give it a lube and chuck it back in and give it a light tap...
and make sure you reset it properly before you put it back in.
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Tomfoolery
Member
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Posted: Mon Apr 21st, 2008 12:38 am |
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Noted, mac and deviant. Mana to the pair of you!
Keep 'em coming...
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Mustard
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| Joined: | Mon Feb 12th, 2007 |
| Location: | Kingston, Australia |
| Posts: | 124 |
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Posted: Mon Apr 21st, 2008 09:21 am |
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Hey Mac D At least your alive lol!Looking forward to seeing the pics! I know what you mean with online time... I'm supposed to be working on a fender eliminator for the 08 zx-10. I keep my time down by only visiting sections I really need to...uhhh well want to need to.
Tom I can't beleive you are going to do this in the back yard. I struggle in my 2.5 car shed out the back, complete with lighting music and computer..
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Tomfoolery
Member
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Posted: Mon Apr 21st, 2008 11:27 am |
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How annoying. My beloved project has ground to a halt already. I can't afford to get petrol to see if it starts.
Oh, well.
Last edited on Mon Apr 21st, 2008 11:23 pm by Tomfoolery
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Tomfoolery
Member
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Posted: Tue Apr 22nd, 2008 08:54 pm |
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Done. Changed up my Euros from the trip to France/Spain, and got some fuel.
The bike wouldn't start. It would intermittently turn over, do nothing or the relay would buzz.
Checking the battery, it only read 12.4 on the multimeter, and needs 12.6 apparently. I'll charge it up on NumberOne's old battery charger I have, and try again tomorrow.
After seeking advice from said family member, I'm going to systematically check all the connections from the starter button down to the battery. I cleaned the button, making sure it was making contact.
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ZXRRDave
Member
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Posted: Tue Apr 22nd, 2008 09:33 pm |
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Check your Earth lead and the main lead to the starter too, as the nut can work loose on it giving intermittent contact.
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Tomfoolery
Member
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Posted: Tue Apr 22nd, 2008 09:40 pm |
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Aye, thanks Dave, all in good time. Next part along is the starter relay/solenoid, then the starter.
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