88 ZX600 Restoration (pictures)

[Superfly]

Hi all, I am new to the forum, wanted to say hi, show a project I was working on, and ask a few questions.

I was looking for a new restoration project, since my other projects are finished, and I picked up these 2 ZX600's and some parts from a local junkyard.



This is the 88



And this is the 86

I could not turn the 88 over by hand, so I had to disassemble the head, fix it up, and re-time it. I can now turn the engine over by hand, and I jumped the starter, and it turned the engine over a few times, so that is promising enough to keep on going.



My garage is a mess...



I took the 2 engines, and made one, and the last photo is where I left off tonight. The funny thing is I picked up that fairing about a year ago, and was going to use it for a project bike, but when I found the 88, I decided to use it on that. I guess you could say I got the bike that matches the fairing... that is kind of funny....

Now my questions. I have almost enough parts for a whole bike, but I am missing 2 main components... Carbs & a Brain. What year carbs will work on a 88 ZX600? Also, what make/models/years of a brain will work on this bike? and does anyone have a lead on any of these parts. I found a set of carbs, but the guy wanted more than I paid for the 2 bikes!

Any tips, tricks, or anything to "look out for" would be greatly appreciated.

[Bhavesh]

Wow...looks like you're doing some heavy work, but good job on the progress so far.

For an '88, my guess (although I'm not 100% sure) is that any carb from 88-97 ZX600C will fit. But you'd have to check the part numbers on the fiche to be sure.

But don't you have an '86 motor in there? Why not get a ZX600A or ZX600B set of carbs? I'm not sure how different the carbs are bewteen the A/B and C models, but to play it safe I would grab them from the former.

As for parts, I've found the cheapest way is to hunt eBay endlessly as people frequently part these bikes out. Email a seller before he knows what they're worth and send him an offer.

What is the brain?

And the last tip I have is: part out both bikes, and buy a newer one that's complete.

[chesthing]

Originally Posted by Bhavesh

And the last tip I have is: part out both bikes, and buy a newer one that's complete.

+1

[kais3rboy]

Lookin good, I restored my 85 too. Good luck. Also 85 to 88 and 89 - 93 looks all the same.

[Superfly]

Thanks for the help on the carb questions.

Brain = CDI, TCI, IC Igniter, little black box, etc....

Originally Posted by Bhavesh

And the last tip I have is: part out both bikes, and buy a newer one that's complete.

I was expecting that!

I like to restore them, fix the engines, rebuild everything, paint it, and then ride it (pleasure, not profit). It is alot of fun, I did this with my other bike(s), and I ride my other bike to work every day, so I am not in a big hurry to complete it.

My question is - why wouldn't you do it?

[ervins]

Wow that is definitely a lot of working going on.

[chesthing]

Originally Posted by Superfly

My question is - why wouldn't you do it?

I guess Bhavesh and I pick our battles a little more prudently. Actually, I have taken on projects like yours in the past. I spent hundreds of hours and 12,000 into a '68 Chevelle that I ended up selling for 7,000 because I grew tired of it. Was it worth the learning experience? maybe, but I can tell you for certain I would never take a project like that on again. But if you enjoy it, it's well worth it, good luck.

[Bhavesh]

Originally Posted by Superfly

Thanks for the help on the carb questions.

Brain = CDI, TCI, IC Igniter, little black box, etc....

Hmm...try picking up the clymer manual and checking out the wiring diagram in the back. I don't own this bike anymore, but from what I remember, the 88-97 harnesses/parts will probably be the most compatible. There are subtle differences between years (ie. latter year bikes lost the ESCS), and a clymer wiring diagram or microfiche can surely clear that up.

Originally Posted by Superfly

My question is - why wouldn't you do it?

The short answer to your question is: limited time, limited money.

The first dirt bike I bought was a 1972 Honda XL-250. It was 1998, and I was 14. I treated that hunk of metal like a queen. Since then I've owned a 79' Kawasaki KD125, a 1996 Toyota Corolla, and a 1989 Kawasaki Ninja 600R. In all cases, after going through all the motions of servicing/restoration/upgrading/modifying, I found that it's always a better idea to buy a complete, newer vehicle. I won't go through all the reasons but there are plenty of them.

[Tbone800b]

Looks like you have a great project going on there. I'm sure others will be along with the answers you need shortly.

[Superfly]

Update.

After a great time rebuilding the engine, I finally got her to fire tonight! Turned out to have a really low compression, so I ended up taking down to the pistons, fixed the problem, cleaned and lapped the valves, and with a good wiring harness, and a good carb rebuild, the bike fired right up. I was even able to get it to idle for a while, so that was the inspiration I needed to keep on going. I know the bike was in the junkyard for a long time, and I must say that it was good to hear the ol' girl running.

[Superfly]

Update

Well, blew that engine, that sucked!





I finally took it all apart, and found 2 bent valves, shatterd piston & connection rod, crankshaft was gouged pretty bad, and the worst part was the crack in the cylinder.....that was a good set of cylinders also...

So I went out and picked up a engine bottom, (no cylinders & heads) and decided to build another engine. This time I decided that I better open up the engine cases to check all the bearings, give them a good cleaning.

A week later (today) I finally finished building the engine, put it in the frame, and started her up. She started quick, and idles perfectly. This new engine sounds really good, but we will see... I decided to take a few pictures while she is running!





Ha, all this work, and she is starting to look like a really ugly 600r!

[joebob47]

have a guestion for you that fairing did you do any fiberglass work to it cause i was told that it would not stick to that kind of plastic if not know of any other body parts i need right side upper fairing and tail pice wife backed into it and knocked it over need cheep parts bad i think she did it on out on spite its an 89 600r also what other year body parts will work and will the c r or any of the other letters they put behind it work

[Superfly]

Before I did any fiberglassing, I roughed up the surface pretty good with a heavy grit sandpaper to give the fiberglass something to grab on to. It has been ok so far, but has not been road tested.

[Tod]

Glad you're back on track after that nasty setback.

It's ugly now, but at the rate you're going, it'll be looking great in no time.

[SLSChic]

I'm impressed!!!!! Keep unpdating us! I'm excited to see her when she's done. Wow you couldn't help but have alot of pride in doing work like that!

[Orion]

Looks good, Superfly! That project will keep you busy for a few weeks.

Joebob47 - how about using some punctuation so the rest of the English speaking folks can decipher your post more quickly? Just some friendly input!

Anyways, Fly, keep at it. If you need some help with the paintjob, I'm an artist in the LA area, too. Keep at it!!!

[joebob47]

sorry, i flunked english and spelling cause i was out ridding, but what adout the body parts any help with that

[webnetxpress]

fiberglassing on the plastic works fine- done to mine before and no problems yet...as said, just roughen up the plastic where you want the fiberglass epoxy to stick to, then make sure you don't overload the plastic with fiberglass cloth/epoxy. a little will go a long way.

[chesthing]

Originally Posted by joebob47

have a guestion for you that fairing did you do any fiberglass work to it cause i was told that it would not stick to that kind of plastic if not know of any other body parts i need right side upper fairing and tail pice wife backed into it and knocked it over need cheep parts bad i think she did it on out on spite its an 89 600r also what other year body parts will work and will the c r or any of the other letters they put behind it work

If you are saying your wife ran into you bike on purpose out of spite, you have a lot bigger problems than replacing some body parts for your bike

[SLSChic]

Originally Posted by chesthing

If you are saying your wife ran into you bike on purpose out of spite, you have a lot bigger problems than replacing some body parts for your bike

ROFLMAO!!! Oh, sorry, yeah what he said^