97 ZX600E project.

Discussion in 'Projects' started by sschering, May 11, 2012.


  1. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    There was wild speculation about who got this bike.. Some said that AV bought this bike. I hate to disappoint but it came home with me..

    I'd just sold my GS1000L and a pocket full of cash compelled me to hook the the trailer and make the 500 mile round trip to bring it home.


    [​IMG]

    [​IMG]

    [​IMG]

    The bike came home with a few known mechanical issues.


    It wouldn't shift (as I found out) below 4th gear.
    It won't rev over 3k but it's easy to start and and runs smoothly.

    I finally have all the parts to put it back together so I thought I'd start a project thread.
     
  2. Andy Capp

    Andy Capp
    Expand Collapse

    5,283
    5
    768
    Location:
    Marysville, WA
    Dang, nice street fighter!
     
  3. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    2 weeks later I made a trip over to Spokane and got all this plus a tank and a few other bits from Daves929

    [​IMG]

    Back at home I dug in to sort out the transmission issue.
    After some messing about I figured out one of the shift forks was bound up.
    I was able to pull the oil pan, remove the forks, set the trans to neutral and re-install the shift forks..

    [​IMG]

    About a week later the gaskets and a few other bits to put it back together arrived
    [​IMG]

    As of today the bike is in more pieces than when I started..
    The wheels came off and went to Skinny_punks house for a new set of tires. (yes I know the shop is a mess)
    [​IMG]

    The carbs still need to be looked at. I have some wiring to do. Turn signals plugs need to be put back and the headlight socket replaced.. I also have a HID kit to install before I can start putting the fairings on.
     
    #3 sschering, May 12, 2012
    Last edited: May 12, 2012
  4. nsrg500

    nsrg500
    Expand Collapse

    2,005
    0
    416
    Location:
    Everett. WA
    :popcorn:
    Stock?
    Fighter?
    Whats the plan Man?:scratchea
     
  5. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    Stock with a few minor tweaks.. I didn't buy a full set of fairings just to hang em on the wall :)

    I came with a V&H SS2R pipe.. I love the way it sounds so I'll keep that.
    PO already put a K&N filter and Dynojet kit in it.
    Front wheel was swapped for a ZX6R wheel.

    I may look into finding a matching ZX6R rear for it.. Same 5" width.. Just lighter and better looking. No point in trying to go wider in the back without swapping swingarms. A 180 tire won't clear the swingarm.

    Down the road but not anytime soon.
    ZZX1200 rear shock swap.
    Racetech fork springs and valve emulators.
    Other options would be finding a set of 41mm cartridge forks or go for the full USD swap.
     
  6. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    Progress today..

    Wheels, radiator, oil cooler, exhaust, calipers back on the bike.
    chain tension set, axles torqued down. Need to go buy some Rotella.

    I started to remove the carbs and found an open vacuum line going to the center two intake boot ports. BIG vacuum leak there.. I'll get that all hooked up properly and see if the carb issue goes away. Not going to pull the carbs for now.
     
  7. Devil_Doc

    Devil_Doc
    Expand Collapse

    4,766
    1
    766
    Location:
    Puyallup-ish
    Subscribed.. :popcorn:
     
  8. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    I got the needles & slides back in the carbs (pulled & re-installed with the carbs still mounted), hooked up the vacuum lines, air box, ram air system (still missing a few bits of tubing) topped the oil and rolled it out to the driveway..

    Choke on, hit the starter.. Rump rump ROAR!! turn it off..

    Silly grin.. :devil: The can is still on the work bench :)

    OK put the tail pipe on. Fire it back up.. Still has the same issue.. Starts and idles perfectly but cuts out and dies past 2k..

    After it's warned up it'll rev to 5k just by pulling the choke lever open but twisting the throttle just kills it.

    After reading a few threads on the ZX forum I'm sure the main and maybe pilot jets are clogged.. Carbs are coming off for cleaning.
     
    #8 sschering, May 21, 2012
    Last edited: May 21, 2012
  9. Devil_Doc

    Devil_Doc
    Expand Collapse

    4,766
    1
    766
    Location:
    Puyallup-ish
    Ha ha ha.. I'm so excited for you. Once you button it up, we need to meet ride out and meet somewhere. 8)
     
  10. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    Yanked the carbs today.. I knew something was up when I cracked the bowl drain screws and nothing came out.

    Found some "WTF is that?" jelly looking crap in the bowls and up into the jets.

    Wierd crap dries to a crusty powder in a few minutes..

    Clearly this is my issue.. jets are all clogged up with this shit..

    [​IMG]

    When I put the bowls into the dip the stuff re-hydrated back into jelly..
    The stuff is tough too.. 30 min in the dip hardy put a dent in it.

    It's in for a long soak.

    Is this what happens when you let ethanol blend gas sit?

    Need to find new bowl gaskets now.. these are dry and cracking..
     
    #10 sschering, May 24, 2012
    Last edited: May 24, 2012
  11. Michael of Burien

    Michael of Burien
    Expand Collapse

    1,118
    0
    366
    Location:
    Burien, WA
    I Ride:
    2005 BMW R1200GS, 2002 Honda CBR954rr (Project)
    I've found that shit too. Crazy stuff it is.
     
  12. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    I wonder if I should dump the fuel in the tank and flush out the lines.
     
  13. nsrg500

    nsrg500
    Expand Collapse

    2,005
    0
    416
    Location:
    Everett. WA
    I found the same crap in my 900rr's bowls.:x After all said and done I have three sets of carbs.
    Swapped out the bowls for a fresher set.

    If the pilots are clogged it wont idle but it will sometimes rev, if you hold it around 4-5k.
    Are your slides working?
    Now you might some of that crap from the bowls up in the bodies now.
    No biggy, just more cleaning and you'll know the condition. You maybe able to rule them out if you still run into issues later.
     
  14. nsrg500

    nsrg500
    Expand Collapse

    2,005
    0
    416
    Location:
    Everett. WA
    P.S.
    Does that bike run a fuel pump? If so, you'll need to flush it too.
    If no pump, than don't worry about flushing it.

    Drain the rest. The carbs will be dry so should be good there?

    Just thinking aloud.:mrgreen:
     
  15. Devil_Doc

    Devil_Doc
    Expand Collapse

    4,766
    1
    766
    Location:
    Puyallup-ish
    :scratchea

    I cleaned the bejeezus out of those..
     
  16. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    Pilots were semi clogged..
    The main and needle jets were completely gummed up with the crap..
    Only the pilot screws and enrichment circuits were clean..

    It would start and idle but would die if you tried to rev it over 2k..
    From the searching I've been doing this look fairly common for old ethanol blend fuel left sitting for more than 6 months.
     
  17. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    It may have been in the tank and got pumped in by the fuel pump when after you put em back on..
     
    #17 sschering, May 25, 2012
    Last edited: May 25, 2012
  18. nsrg500

    nsrg500
    Expand Collapse

    2,005
    0
    416
    Location:
    Everett. WA
    I had the impression your mains had an issue. Other wise it wouldn't have die after opening the throttle.
    I've also ran into this; Ya get em cleaned and running spot-on. Then about two tanks later it starts acting up. It's usually little bits of crap finally brake lose and start clogging things up again.

    Lots of people have had good luck with adding Seafoam to get things cleaned up.
    That's after everything has been cleaned and running good. It helps to keep thing flowing.

    :popcorn:
     
  19. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    Yeah.. 12 hours in the dip put a dent in the stuff but there was still some left..

    I wiped what I could out of the bowls and put em back in the sip along with the all the jets.

    I'll be sure to run seafoam in it after it's back together.
     
  20. sschering

    sschering
    Expand Collapse

    2,656
    0
    591
    Location:
    Kennewick, WA
    48 hours if parts dipping later I have declared the carbs clean..

    The dip hardly touches this gelled gas.. I had to hand clean a few spots with q tips and carb cleaner even after dipping.

    The 2 spacer washers that sit on top of the dynojet needle clip were MIA on carb #1.
    I found some small washers in the hobby bin and drilled em to fit..

    Floats are all set to 11mm..

    After I got them together I did a bench sync on the rack..

    All I need to do now is swap on the new tank and flush the rest of the fuel system.


    [​IMG]



    While I was waiting for the carb parts to soak I took on a small issue with the coils.
    2 of the well nuts that mount them were damaged or missing. One mounting bolt was gone along with all of the spacers.

    I put in new well nuts, and turned some 20mm spacers from 1/2 aluimnum bar.
    [​IMG]
     
    #20 sschering, May 27, 2012
    Last edited: May 27, 2012
Loading...
Similar Threads Forum Date
1995 or 1997 ZX600E exhaust Gear, Parts, & Accessories Apr 21, 2014
Need ZX600E transmission help Mechanical & Technical Apr 20, 2012
97 Kawi Zx600e Streetfighter Motorcycles Mar 30, 2012
Looking for a project dual sport Motorcycle Talk Jun 23, 2015
project day Oregon Apr 15, 2013

Share This Page