88 ZX600 Restoration (pictures)

[itjstagame]

Ouch, it always hurts to see a hole in a crank case. That's the worst sort of disease a machine can have. Just happened to my friends CRX too.

Glad to see it's running again.

[Superfly]

I have been making some good progress on the project bike. Starter clutch went out, and I was having some transmission problems, so I opened her up one more time, fixed the starter clutch, fixed the transmission, and now it is time for some fun stuff (basically at this point, anything besides the engine!)



This is her "ok side" since she does not have a "good side" yet!!



I finally fixed the brake problem I was having (Actually, I had no brakes, that was the problem!) so I was able to take her out for a bit, I was able to get the bike up to 45-50 (back alley) and she was a tad sluggish, made some modifications to the carbs (2 turns out on the jets, made a world of difference) and I must admit, this bike has a some zip to her, considering my main bike is a V-twin, it is a completely different feel.

I think the next step, is to start on the bodywork, and get a few more pieces.

[Lawn Masters]

Its makin progress. I had a "ventilated" block myself on a ZX1000, glad ya fixed that issue. Just some more plastic I bet, and obviously some paint and it'll look at least alright if not super.

[SixFiveOh]

Kool! Looking for an early 80's CB750F to restore myself (sorry guys - I know it's a Honda but I had one when it was new).

[ervins]

Shaping up!

[Superfly]

Restorations are a lot of fun, I have done a few, and I really enjoy it. I have always liked the looks of this bike, and have always wanted one, so I figure I could build the bike I wanted, instead of buying one. As soon as you can get past the "Ugly Phase" that is when the bike really starts to take shape. Been doing alot of engine work lately, and the only thing left to do on the engine is to re-seal the oil pan. So now it is on to the bodywork, and then prime it.

[bmwe30is]

Awesome man!

I gotta synch the carbs on mine this weekend, I might take 'em off to clean them out one more time. I think they may have sucked in some rust when I got the bike running last month.

[Superfly]

Been making great progress on the restoration, starts fast, and the engine is strong. I checked the compression tonight and it was right in line. However, Plug #1 was really fouled, whereas 2,3, &4 were a nice shade of brown. Plus I am getting a popping during deceleration. I have gone thru the carbs twice, swapped out the plug/wire/caps and the coil, but she still stumbles a bit. Close, but not perfect yet.







The red and blue rims are killin' me!

So today, I went down to the DMV, registered the bike, got my temporary tag (the red 9 on the tail of the bike) and finally had a chance to go out on the freeway and open her up a little bit. Not bad at all, the bike has a good feel to it.

I have also been collecting the parts needed for the 86 I have, and started assembleing that bike last week. All I have to say is the engine does NOT like going back into the frame!

[itjstagame]

It looks really nice. I wish I had the time or place (or tools) to do this. I love taking stuff apart. As such I have gotten really good at throwing things back together quickly, it's amazing that it only takes like 15 mins to put the gas tank, fairings, windshield, instrument cluster back on a very naked looking bike.

I've not swapped as much as you, and I've always had a 'popping' on deceleration, as well as my current issues. I was curious about putting the jets in or out of turn, I've seen people mention this a lot, I figured it ment somekind of external idle screw or mixture screw on the carbs (turn in an amount and count), but are we talking the main idle jet inside? Would that stay at the same number of turns if not tightly down? I don't think I paid any attention when I rebuilt mine, I think they're lightly seated at the bottom.

[zx600c]

man, kudos. U sure have came a long way with this bike and she is really starting to look great!!! I am proud of ya man.. I know I got a zx600c and man the last c i had didn't feel this good to drive, I can now cruise at 95 and not feel a vibration lol... Itsagame!! The jets inside the carb like the low speed idle jet or the "pilot jet" screws all the way in tightly as far as i know, but not to tight. Guess u could say lightly lol... The air mixture screws are in the front of the carbs sometimes you have to drill through the thin layer of metal to get to them. Just becarful doing this..This is my bike now!!

[forest1000]

Very nice work. It's been a struggle but it will be worth it in the end.

[Superfly]

Thanks!

I am really diggin' the look of the tail with no mud flap. I must might fab up a bracket for the turn signals & license plate and keep the look.

The final paint job has been put on hold, Last month my garage was broke into and they stole alot of my tools, and my new craftsman air compressor and I decided not to buy another one while I live here, because last week my neighbors garage was broke into also. So she will be "Rattlecan Black" for a little bit. Damn thieves put a stop to the restoration!

[4jacks]

Dude, you are my new freaking Hero..

[4jacks]

oh, that freaking SUCKS about your tools!!! !

Man you gotta keep dem locked up, Theives love to sell tools, there is a BIG black market for tools!

[Superfly]

I finally had a chance to take the Ninja on a trip. I went over to a friends house, about 20 miles each way, and all went fairly well. I started getting a high pitched squeaking sound from somewhere (something with the tires/rims/ or brakes) but could not really dig into it because I was on a freeway and hard to diagnose a problem with a moving bike! I made a few adjustments to the brakes, but on the way home, it did it again. I am going to have to fix that before I take it out again!

Then, the unbelieveable happend on the way home, all the sudden, I lost everything, and the bike was bucking & kicking like the power was on/off/on/off (going down a mountain on the freeway going about 55-60 mph). I was able to get off the road, took the seat off to see what was going on, and I lost my negative battery terminal screw! I was like... CRAP! I was able to rig it up to get home.

All in all, not too bad, I was able to see what "bugs" were still in the bike. I think I am going to clean the tank out really good again, because I saw some dirt at the bottom the carbs, which made the bike run bad a lower RPM's, but when it was around the 8k range, I could feel the bike kick in.

[Bike_Poseur]

Originally Posted by Superfly

I finally had a chance to take the Ninja on a trip. I went over to a friends house, about 20 miles each way, and all went fairly well. I started getting a high pitched squeaking sound from somewhere (something with the tires/rims/ or brakes) but could not really dig into it because I was on a freeway and hard to diagnose a problem with a moving bike! I made a few adjustments to the brakes, but on the way home, it did it again. I am going to have to fix that before I take it out again!

Then, the unbelieveable happend on the way home, all the sudden, I lost everything, and the bike was bucking & kicking like the power was on/off/on/off (going down a mountain on the freeway going about 55-60 mph). I was able to get off the road, took the seat off to see what was going on, and I lost my negative battery terminal screw! I was like... CRAP! I was able to rig it up to get home.

All in all, not too bad, I was able to see what "bugs" were still in the bike. I think I am going to clean the tank out really good again, because I saw some dirt at the bottom the carbs, which made the bike run bad a lower RPM's, but when it was around the 8k range, I could feel the bike kick in.

How are you gonna clean the tank? Are you just going to fill it with muriatic acid and rinse, or are you going to do a whole lining-kit thing with kreem or por15?

I'm curious because I just cleaned my rusty tank out yesterday and I am thrilled with the results. Nothing but silver metal inside!

[Superfly]

The tank was previously done with Kreem (I prefer Por-15) but it sat in the desert for a bit with not gas cap. I am going to try to just clean it out, but worst case scenario will be the POR 15 Heavy Duty repair kit which will strip out the old Kreem, and put a new coating of POR-15.

[flame220]

See the next post.... I hit the submit button before typing what I wanted to say

[flame220]

Sorry, I hit the submit button too soon !

The reed valves are causing your popping when decelerating.
If you can get some 1/4" aluminium plates manufactured so you can remove the reed valves then cap off the rest of the setup you will find it will stop popping.
I fitted UK spec camshaft cover & air cleaner to my US spec ZX600C, it runs sweet now with no popping.
1 3/4 turns out is good for the idle screws.
Hope that helps

[Superfly]

Thanks for the advice on the reed valves, I will definately do that. I was considering removing the emissions crap, and you helped me make up my mind! I am still in the process of "fine tuning" so any and all advice is welcome.