88 ZX600 Restoration (pictures) - Page 3

flame220 · 08-29-2006

US bike with non US camshaft covers

itjstagame · 08-30-2006

Not to sound completely retarded, maybe it's because it's 5am here, but what's a reed valve? Something to do with the emmissions? What all is required to remove the emmisions, or do the different cam cover and cams help? I could use more room under there, I don't need all the EGR tubing.

Superfly · 08-30-2006

The reed valve is on top of the valve cover. If you look on Flame220's picture, it is not there, but on top of the US engines, there are 2 valves on top of the valve cover that go into the emissions stuff. I pulled my cover off last night, took the reed valves off, tapped 2 threads where the air holes are on each one (they are pretty small), and plugged the holes. After that, cap off the 2 nozzles on the carbs (1 & 4, like the red cap that is on carb #3). The only thing that would be left is to plug the hole in the top of the airbox where the tubing goes. While the valve cover is off, it would be a great time to check (or re-check) valve clearances.

flame220 · 08-30-2006

Quote:

Originally Posted by Superfly

While the valve cover is off, it would be a great time to check (or re-check) valve clearances.

I thought exactly the same thing when I swapped the covers over on my engines.... then I tried to find a wrench small enough to hold the dumb little square (maybe 1/8" max) on the end of the adjusting screw.
I tried to hold the square with a 3" adjustable wrench & eventually gave up because
1. The wrench just wasnt slim enough
2. The frame rails got in the way.

Superfly · 08-30-2006

The locking nut on the valves are a 8mm, so I just broke it loose, unscrewed it a bit, and then I took a socket (6mm I think) and found some old Vacuum line tubing, jammed it in there (I never used the socket anyways!) and it gripped the end of the valve adjusting screw enough to adjust it. Throw a universal joint in there somewhere, and you have a valve adjuster tool.

flame220 · 08-30-2006

There you go...

http://www.mandp.co.uk/productInfo.aspx?catRef=500607

1fast97gsx · 08-31-2006

Wow looks awesome. I'm doing an 88 600 as well. I got the motor in and got it to start but I'm having a problem getting it to run smoothly at idle and once it dies out it won't restart. I'm guessing the carbs are gunked up from sitting for 1+ years? In order to start it the battery has to be at a full charge and then it will start with full choke and idle at like 6000 rpms or so. If I close the choke to anything lower than 2500 rpm it will just die out and generally not restart for a while. If I keep the choke open and let it idle at 3000 or so it will stay running, but if you crack the throttle open it will die. As you can probably tell I'm not a carb guy .. don't know crap about them! Once I figure out that issue and get it to hold a steady idle and reve properly I should be good to paint the plastics and take it out for a ride. So far so good!

Superfly · 08-31-2006

When you clean the carbs, the idle will settle down alot. After the 2nd dipping of the carbs on the bike, it was holding idle very well.

1fast97gsx · 08-31-2006

I'll give that a try tomorrow. Also, going from the left coil do you remember what order the spark plug wires go? looking straight down at the coils ( as if you were sitting on the bike ) I have 1,4,2,3 I think. 1 and 4 from the left coil and 2 and 3 from the right. When I got the bike it wasn't running and the wires just dangeled so I had no idea what went where.

Also, what colors are you painting your bike? Any idea on why my bike wants to die out when I twist the throttle to rev it? Also carb cleaning related?

flame220 · 08-31-2006

You have the spark plug wires in the correct order ( 1,4,2,3) . The low tension wires to the coil should be ( from left to right)

Left coil....Red on the left, black on the right
Right coil.... Red on the left, green on the right.

As Superfly advised you, take your carbs off & clean them out properly, the idle jets will probably be blocked.

1fast97gsx · 09-01-2006

cool, thanks!

Superfly · 10-15-2006

Wow, this bike is a blast! I have put a little over 2k miles on it using it as a daily ride, and this is a very solid motorcycle. All the numbers came back clean & clear from the DMV & CHP, and now I can get real tags. While I am waiting for final paint, I added some "fun" parts. Stage 1 jet kit, K&N filter (not pods) 4-1 V&H, dropped a tooth on the front sprocket, and the bike pulls and sounds great. Added a braided brake line on the back, and the next time I have the fairing off, I am adding braded brake lines on the front.

Since the 88 is doing well, I decided to start working on the 86. Still trying to find the last bit of parts needed to take the bike for a test ride. The rebuilt engine starts good, but I only have had the bike running for a few minutes.

A couple of pictures of them together.

I love these old ninjas...

itjstagame · 10-16-2006

Me too! They look great!

It's cool you've almost got the same bike, '88 600R, full V&H, K&N (not pods) and stage 1! It does pull quite nice and handles quite well.

First thing I did when I got my bike was put braided stainless steel lines on, the front is just as easy as the rear, there's no reason to take the front fairing off. There's plenty of space infront of the horn all the way to the brake reservoir. The one annoyance is that the horn bolts to the old spitter for left/right front lines, so my horn just rattles a bit now, not that I can hear it over the V&H. The lines made a big difference to my front brakes (added sintered ceramic pads while I was at it). I didn't notice as much of a change in the rear really. In the front I made sure to get longer lines with a double banjo right off the reservoir, no more of that splitter thing, I think that helped the pressure the most.

What color will final paint be?

Superfly · 10-17-2006

Thanks for the input on the brakes, I think it is going to be my weekend project, because I am going to add a Voltmeter to the bike also (I guess I have just rode too many early 80's Yamahas & Suzuki GS's!) and really like to know what is going on with the charging system.

Final paint is a tough one. Still have not come up with anything I am crazy about yet. I am thinking of black for the main color, Red major secondary color, and silver or white for a touch of a different color. The black "Mad Max" bike withe the white Kawasaki on the chin is fine for the moment, because I really wanted to see where the last bit of imperfections in the body/fairing were. Since my main bike spun a connection rod berring (on a motorcycle run... 400 miles from home!) The ninja has been my daily ride, and might have to wait untill the 86 is running strong to paint. Always something!

The setup we are running on these bike are really good. I am very please with the performance of this bike, and the jet kit makes a world of difference! The full V&H screams pretty well in the powerband.

Hopefully the next post will have more progress on the 86. I just recieved my POR-15 kit for the tank, and I forsee a test ride in the near future!

itjstagame · 10-17-2006

POR 15 is great stuff.

Yeah, hopefully I'll have the time this winter to completely disassemble and rebuild mine. It is always something, this one car I was trying to sell, needed rear brakes, right after I fixed that it blew two brake lines, right after I fixed that and was very happy with the car it wouldn't start the next morning... 1 starter later. Vehicles are headaches

.

Good luck with the bike.

SlowNinja · 10-17-2006

I like the exposed frame on the 86, actually looks like a sport bike. 88-97 (my year) the frame was hidden, I actually think it makes the bike look cheaper.....

sebastian1000 · 10-18-2006

yeah I also like the bike better with the frame exposed....it gives you something to shine up later on hehe. but hey man you are definately kicking some major butt on these bikes! so what is the total dollar amount invested thus far? hours invested? very cool thread.

Fun Fun.

itjstagame · 10-18-2006

I think the frame looks nicer mostly because that's the way most of the newer bikes look, well at least 5 years ago, some now too.

Does anyone know the weight, hp difference on the 600As vs the 600Cs? I never really paid attention but there's one for sale near me.

SlowNinja · 10-18-2006

Far as I know they were right about the same. If there was a weight/Hp difference it was pretty small.

ervins · 10-18-2006

Wow that bike came a long way. You did a great job brother. Excellent!

08-30-2006	#43 (permalink)
Superfly Rippin Ninja's heads off! BTK Expert Join Date: Apr 2006 Location: Los Angeles, CA Posts: 392	The reed valve is on top of the valve cover. If you look on Flame220's picture, it is not there, but on top of the US engines, there are 2 valves on top of the valve cover that go into the emissions stuff. I pulled my cover off last night, took the reed valves off, tapped 2 threads where the air holes are on each one (they are pretty small), and plugged the holes. After that, cap off the 2 nozzles on the carbs (1 & 4, like the red cap that is on carb #3). The only thing that would be left is to plug the hole in the top of the airbox where the tubing goes. While the valve cover is off, it would be a great time to check (or re-check) valve clearances. Last edited by Superfly : 08-30-2006 at 11:32 AM.

08-30-2006	#45 (permalink)
Superfly Rippin Ninja's heads off! BTK Expert Join Date: Apr 2006 Location: Los Angeles, CA Posts: 392	The locking nut on the valves are a 8mm, so I just broke it loose, unscrewed it a bit, and then I took a socket (6mm I think) and found some old Vacuum line tubing, jammed it in there (I never used the socket anyways!) and it gripped the end of the valve adjusting screw enough to adjust it. Throw a universal joint in there somewhere, and you have a valve adjuster tool. Last edited by Superfly : 08-31-2006 at 12:58 AM.

10-15-2006	#52 (permalink)
Superfly Rippin Ninja's heads off! BTK Expert Join Date: Apr 2006 Location: Los Angeles, CA Posts: 392	Wow, this bike is a blast! I have put a little over 2k miles on it using it as a daily ride, and this is a very solid motorcycle. All the numbers came back clean & clear from the DMV & CHP, and now I can get real tags. While I am waiting for final paint, I added some "fun" parts. Stage 1 jet kit, K&N filter (not pods) 4-1 V&H, dropped a tooth on the front sprocket, and the bike pulls and sounds great. Added a braided brake line on the back, and the next time I have the fairing off, I am adding braded brake lines on the front. Since the 88 is doing well, I decided to start working on the 86. Still trying to find the last bit of parts needed to take the bike for a test ride. The rebuilt engine starts good, but I only have had the bike running for a few minutes. A couple of pictures of them together. I love these old ninjas... __________________ The 86 & 88 Ninja Build Last edited by Superfly : 10-15-2006 at 01:11 PM.

10-17-2006	#54 (permalink)
Superfly Rippin Ninja's heads off! BTK Expert Join Date: Apr 2006 Location: Los Angeles, CA Posts: 392	Thanks for the input on the brakes, I think it is going to be my weekend project, because I am going to add a Voltmeter to the bike also (I guess I have just rode too many early 80's Yamahas & Suzuki GS's!) and really like to know what is going on with the charging system. Final paint is a tough one. Still have not come up with anything I am crazy about yet. I am thinking of black for the main color, Red major secondary color, and silver or white for a touch of a different color. The black "Mad Max" bike withe the white Kawasaki on the chin is fine for the moment, because I really wanted to see where the last bit of imperfections in the body/fairing were. Since my main bike spun a connection rod berring (on a motorcycle run... 400 miles from home!) The ninja has been my daily ride, and might have to wait untill the 86 is running strong to paint. Always something! The setup we are running on these bike are really good. I am very please with the performance of this bike, and the jet kit makes a world of difference! The full V&H screams pretty well in the powerband. Hopefully the next post will have more progress on the 86. I just recieved my POR-15 kit for the tank, and I forsee a test ride in the near future! __________________ The 86 & 88 Ninja Build

10-18-2006	#57 (permalink)
sebastian1000 Needs A Real Job BTK Expert Join Date: Jul 2006 Posts: 4,068	yeah I also like the bike better with the frame exposed....it gives you something to shine up later on hehe. but hey man you are definately kicking some major butt on these bikes! so what is the total dollar amount invested thus far? hours invested? very cool thread. Fun Fun. __________________ *ZULU X-RAY - 10 ROMEO*

08-29-2006	#41 (permalink)
flame220 Its all about the engine BTK Intermediate Join Date: Mar 2006 Location: Lincoln, England Posts: 129	US bike with non US camshaft covers

08-30-2006	#42 (permalink)
itjstagame Information Assimilator BTK Expert Join Date: Mar 2006 Location: Troy, NY Posts: 615	Not to sound completely retarded, maybe it's because it's 5am here, but what's a reed valve? Something to do with the emmissions? What all is required to remove the emmisions, or do the different cam cover and cams help? I could use more room under there, I don't need all the EGR tubing.

08-30-2006	#46 (permalink)
flame220 Its all about the engine BTK Intermediate Join Date: Mar 2006 Location: Lincoln, England Posts: 129	There you go... http://www.mandp.co.uk/productInfo.aspx?catRef=500607

08-31-2006	#47 (permalink)
1fast97gsx Newbie Join Date: Mar 2006 Posts: 19	Wow looks awesome. I'm doing an 88 600 as well. I got the motor in and got it to start but I'm having a problem getting it to run smoothly at idle and once it dies out it won't restart. I'm guessing the carbs are gunked up from sitting for 1+ years? In order to start it the battery has to be at a full charge and then it will start with full choke and idle at like 6000 rpms or so. If I close the choke to anything lower than 2500 rpm it will just die out and generally not restart for a while. If I keep the choke open and let it idle at 3000 or so it will stay running, but if you crack the throttle open it will die. As you can probably tell I'm not a carb guy .. don't know crap about them! Once I figure out that issue and get it to hold a steady idle and reve properly I should be good to paint the plastics and take it out for a ride. So far so good!

08-31-2006	#48 (permalink)
Superfly Rippin Ninja's heads off! BTK Expert Join Date: Apr 2006 Location: Los Angeles, CA Posts: 392	When you clean the carbs, the idle will settle down alot. After the 2nd dipping of the carbs on the bike, it was holding idle very well.

08-31-2006	#49 (permalink)
1fast97gsx Newbie Join Date: Mar 2006 Posts: 19	I'll give that a try tomorrow. Also, going from the left coil do you remember what order the spark plug wires go? looking straight down at the coils ( as if you were sitting on the bike ) I have 1,4,2,3 I think. 1 and 4 from the left coil and 2 and 3 from the right. When I got the bike it wasn't running and the wires just dangeled so I had no idea what went where. Also, what colors are you painting your bike? Any idea on why my bike wants to die out when I twist the throttle to rev it? Also carb cleaning related?

08-31-2006	#50 (permalink)
flame220 Its all about the engine BTK Intermediate Join Date: Mar 2006 Location: Lincoln, England Posts: 129	You have the spark plug wires in the correct order ( 1,4,2,3) . The low tension wires to the coil should be ( from left to right) Left coil....Red on the left, black on the right Right coil.... Red on the left, green on the right. As Superfly advised you, take your carbs off & clean them out properly, the idle jets will probably be blocked.

09-01-2006	#51 (permalink)
1fast97gsx Newbie Join Date: Mar 2006 Posts: 19	cool, thanks!

10-16-2006	#53 (permalink)
itjstagame Information Assimilator BTK Expert Join Date: Mar 2006 Location: Troy, NY Posts: 615	Me too! They look great! It's cool you've almost got the same bike, '88 600R, full V&H, K&N (not pods) and stage 1! It does pull quite nice and handles quite well. First thing I did when I got my bike was put braided stainless steel lines on, the front is just as easy as the rear, there's no reason to take the front fairing off. There's plenty of space infront of the horn all the way to the brake reservoir. The one annoyance is that the horn bolts to the old spitter for left/right front lines, so my horn just rattles a bit now, not that I can hear it over the V&H. The lines made a big difference to my front brakes (added sintered ceramic pads while I was at it). I didn't notice as much of a change in the rear really. In the front I made sure to get longer lines with a double banjo right off the reservoir, no more of that splitter thing, I think that helped the pressure the most. What color will final paint be?

10-17-2006	#55 (permalink)
itjstagame Information Assimilator BTK Expert Join Date: Mar 2006 Location: Troy, NY Posts: 615	POR 15 is great stuff. Yeah, hopefully I'll have the time this winter to completely disassemble and rebuild mine. It is always something, this one car I was trying to sell, needed rear brakes, right after I fixed that it blew two brake lines, right after I fixed that and was very happy with the car it wouldn't start the next morning... 1 starter later. Vehicles are headaches . Good luck with the bike.

10-17-2006	#56 (permalink)
SlowNinja Clutch Cadet BTK Expert Join Date: Oct 2006 Posts: 358	I like the exposed frame on the 86, actually looks like a sport bike. 88-97 (my year) the frame was hidden, I actually think it makes the bike look cheaper.....

10-18-2006	#58 (permalink)
itjstagame Information Assimilator BTK Expert Join Date: Mar 2006 Location: Troy, NY Posts: 615	I think the frame looks nicer mostly because that's the way most of the newer bikes look, well at least 5 years ago, some now too. Does anyone know the weight, hp difference on the 600As vs the 600Cs? I never really paid attention but there's one for sale near me.

10-18-2006	#59 (permalink)
SlowNinja Clutch Cadet BTK Expert Join Date: Oct 2006 Posts: 358	Far as I know they were right about the same. If there was a weight/Hp difference it was pretty small.

10-18-2006	#60 (permalink)
ervins MOM Sept 2006 Forum Supporter Join Date: Jan 2006 Location: Castro Valley, CA Posts: 11,825	Wow that bike came a long way. You did a great job brother. Excellent! __________________ Black 2006 ZX-10R http://cache.www.gametracker.com/ser...0/b_560x95.png

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