Used choke cable $10.88 picked out. Got GM running!
Bought 1/4″ fuel line at AZ for missing airbox drain tube at noon.
Posted in Uncategorized by green
Carbs Cleaned!! 43,295 miles
Just finished carb clean job! 2 of 4 air jets to pilot jets were clogged shut. Gently poked them out with twisty tie. Evinrude “Engine Tuner” could not dissolve clog. Finished carb reassmbly last night.
New fuel filter
Cleaned and oiled Uni Air filter
Inspected, cleaned, and checked gaps on all 4 plugs
re-routed 2 hose connections properly, blew out oil filled rear evap line and re-routed it correct. Fix potential ram air leak.
re-set pilot screws from 3.4 turn to 2 turns
re-set idle screw adjuster now to where it supposed to be.
So status?
Started her up for first time in 2 weeks. Hard to get fuel going and start, but first time ever she started up cold with push button! rough at first, and I have to fix the throttle cable adjustments (tried to match to my eye the turns on the adjuster but the throttle return lags quite a bit.)
It now can actually idle down to 1300 rpm without dying which it never did before!
It’s all about cleaning out thoroughly those pilot jets and pilot housings!!
Main jets: 140 Pilot jets: 35 Keihin. Needles: N1VC
Set pilot mixture screws to 2 turns out.
Posted in Uncategorized by green
Actual cleaning, Pilots out: 5pm – 10:20pm
cleaned out all parts with engine tuner. 2 of 4 pilot jets clogged. Reassembled all carbs correctly late. Late dinner with C.
Posted in Uncategorized by green
Start carb clean
Start carb tear down and cleaning all out. About 3.5 hours – 4 hours of work.
Had to stop – no small flathead to pull pilot jets.
Posted in Uncategorized by green
Norcal hills trip (central cali), turns turns turns – 1st trip!
I wonder if a bunch of people here have done this trip. Redwood / Pinehurst. Would be certain many CA ZXers know to head there.
Oakland start.
Snake to Skyline Blvd, keep going all the way back down to 580 via Grass Valley Rd and Golf Links Rd. Parallel the 580 south towards Estudillo towards Lake Chabot.
Wrap around Lake Chabot, and we drove thru Castro Valley into Hayward and stopped for some eats at Buffalo Bills.
Back on bike, backtracked into Castro Valley. Seven Hills Road to Redwood and then right onto Pinehurst on insane turns over and over over the pass down into Moraga / Canyon area, at T straight on thru Canyon following Pinehurst thru Redwood forest to some crazy curves back up to Skyline Blvd.
Gorgeous views.
Posted in Uncategorized by green
Bought new Alpinestars! armored jacket (used from CL guy, but new with tags and hanger!)
Size 44 fits me perfect! Quite visible too which I like. Stoked!
Posted in Uncategorized by green
My first ZX6e!! Bought last night 9pm! Pics, Fell in love on the ride home.
Just bought this bike for $900.00 cash last night. Runs a little rough, perhaps a weary clutch too. 43,174 miles on it. Some damage from PO low siding it in a turn.
So psyched to get this bike. You might guess I like Kawasaki Green.
PO fueled with 87 octane. And fuel present in tank was 8 month old 87 octane. Hard to start, sort of rough idle (big surprise). Bad. I put in 3.5 gal of 91 Octane down the street from purchase and that already made it ride better. Starts not great, had to bump start it three times to get it to run after sitting 5 days by previous owner for my test ride. Electric started once after a stall. Then had to bump start it again at gas station.
Might try the SeaFoam stuff. Does that work well?
This bike destroys my Katana 600 I owned forever. I love it.
Posted in Uncategorized by green
DIY waterpump rebuild (proper thread). Published from old zzr-international.co.uk site by dirtdoggle
DIY waterpump rebuild (proper thread)
Postby dirtdoogle » Tue Aug 21, 2012 11:43 am
I apologise in advance for my poor pics, nerve damage in my right wrist makes me shake a wee bit 😉
What you need:
A ZZR4/600/K/D, haven’t done one on the N/E but I think they’re the same
10 and 8mm spanners
Many hammers
Cigarettes
Socket set
Assortment of decent screw drivers
Circlip pliers
Extensive knowledge of grunting and swearing
Bearing puller really, really helps
Parts: Loctite sealant or similar
A wee bit of grease (if pedantic like myself)
Bearings: Two 12x28x8 stainless steel and must be 2RS sealed type (these cost me a grand total of $5NZ)
12 x 28 x 7mm radius oil seal
12mm external circlip
Rear water pump o-ring http://www.ronayers.com/ProductDetails/ … KU/1088282
Front water pump housing seal http://www.ronayers.com/ProductDetails/ … KU/1088281
Righto what you want to do:
Remove your bottom fairing (no pics, my bike obviously hasn’t got one, fairings are silly)
Drain the coolant, if unsure of how to do this, step away from the bike and go have a coffee.
Remove both hoses to the water pump
Un do the top and bottom 10mm bolts on the front of the pump
Ease the pump out
Now the fun begins.
Remove the remaining bolts from the pump cover and open ‘er up
Should look like this, hopefully…
Image
Now flip it over so you’re looking at the back
In theory, you’ll be looking at an oil seal
Image
Pop this wee fellow out and you’ll be able to see a circlip on the shaft holding the bearing in
Whip that out with the previously mentioned circlip pliers (or get real handy with a flat blade screw driver…)
Now you can grab you hammer assortment! Yay!
Place the pump on blocks of wood, impeller facing down and make sure it’s not hitting the wood
Gently drive the pump shaft out, this may require the grunting and/or swearing you got yourslef before starting this job.
Once you’ve managed to get the impeller and shaft out, flip it over and you should see this
Image
I didn’t need to replace this seal on mine, but do note how it sits on yours (this seal causes a lot of drag, I’m currently trying to think of a mod to get rid of it)
Ease it off and you’ll see this
Image
If not, you’ve started working on the wrong bike and it’s not my problem
Now, select your favourite long screw driver (unless you have a bearing puller, then you win) and drive the bearing on the engine side out, heat can help here, I’m a sucker for making shit hot, so I put it in the oven for half an hour at 150 celcius, made life superbly easy!
Once that bearing is out, flip the pump, burn your hands (oops!) and gently tap the other side out, I used a socket and wooden mallet for this one and being heated, they popped right out (the pump I did before hand wasn’t heated and was a prick to do)
Now you’ll have a completely empty water pump! The end.
No not really…
I’m sorry for the lack of pictures, most of the ones I took are too blurry to make sense 😆
Clean everything, I cannot stress this enough, if you’re spending time doing something like this, make it perfect
Is it clean yet?
Good.
Insert the new impeller side bearing and gently drive it in, makes life easier yet again if the pump is a bit warm, and I always put bearing in the freezer before installation, easier than peeling a potato with a gun.
It should look like this Image
If not, you’re a womble and should stop sniffing glue
Clean this wee thingy Image I used brake cleaner and a razor blade, but I’m slightly pedantic.
Apply a very thin smear of the loctite sealant stuff, or whatever is on hand (blood, feces etc)
It’ll push right in if you freeze it… otherwise, get a socket (I think 16mm was about right) and very gently tap it in
Once that’s nice and snug, fit that odd little spring loaded washer/seal, making sure it’s alligned correctly on the little dimples.
I think fitting a teflon washer between that and the impeller will get rid of the ridiculous drag it causes
Now, find the impeller, put a thin smear of grease on it and push it through (yet again, heat/cold parts help, but hammers work too)
Once you have that in, insert the new bearing in the engine side, double check that the impeller has clearance on the housing too, otherwise you’ll have a big mess
Fit the circlip
Apply a tiny smear of the sealant rubbish on the outside of that new oil seal and push it firmly in to place.
Don’t forget that new rear O-ring!
Flip it over again, check you’ve still got clearance on the impeller
Mount the housing on the motor and turn the impeller until you feel the shaft slip in to place of it’s drive
Clean the mating surfaces on the housing, fit new seal (or just use more sealant, not my problem)
Fit the from cover and bolt ‘er up
Polished front is optional and not worth doing on a faired bike
Image
I hope this helps someone, it’s long stupid and rambling, but you’ve made it this far and good luck to you
Will update once I have found a decent alternative to the inside seal 🙂
———-
Green Magic Man (me) add this to the post:
I thought I should pass along this research. An Italian at the German zzr site said he did his ZZR600 D model water pump with this Honda part which is the same seal for the oil seal in the Kawi.
Part # 91201-mf2-003
I looked it up and it shows up indeed as:
Honda 91201-MF2-003 OIL SEAL (12X28X7) — OIL SEAL ( 12X28X7) (Honda Code 2073054), OIL SEAL …
For US $3.50 at partzilla, US $4.50 at local Kawi dealer.
I will order one and try to confirm this fits in my ZZR600 water pump. I think that enables me to source all the parts at this point.
This was the post:
http://www.zzr-rg.co.uk/forum/viewtopic.php?t=5163
Also, cross referenced another part, this one is a Kawasaki part a forum poster says fits too:
92049 1416 said this fits but is not common knowledge it fits most Kawasakis.
And same guys says this for the mechanical seal part: 49063 1055
Here is my source thread for this: http://www.kiwibiker.co.nz/forums/showt … -weep-hole
—
I can indeed confirm this Honda oil seal part fits the ZX6E / ZZR600 model :clap: :
Honda part #: 91201-MF2-003
description: OIL SEAL (12X28X7)
price: US Dollars $4.99
I had to special order the part and installed it today. Very nice fit. This is the oil seal that goes around the impeller shaft at the very end (not the wider O Ring that goes around the water pump impeller housing.
Posted in DIY, repair and tagged DIY, how to, Kawasaki, rebuild, water pump, Zx6e, zzr-international.co.uk, zzr600 by green
Electrical wiring diagrams ZX6E ZZR600
Here’s some of the wiring diagrams for reference on the road.
Posted in Uncategorized by green
1995 trip Switzerland
July 1995.
I rode the ’78 CX500 Honda again from Utrecht to Verbier, Switzerland. It’s about 607 miles one way.
I rode two days each way and stayed in Verbier for about 5 days of shooting.
I used about 25 gallons for 1220 miles altogether at about $100-$125 USD. Which got me about 49 mpg for this trip.
Left Holland about noon. Drove through Maastricht, NL; Fameck, France; Frouard, Epinal and stopped in Bensancon, France for the night.
I had dinner in Epinal France at 8:40pm. Ok onto the funny story for the night.
My French is, how you say, not very good.
I try to find this universite hostel in Bensancon. I cannot. I go back a few times to a massive posted map of the town. An old man watches me and watched me return looking lost. He approaches and more or less (as far as I can understand), the hostel is closed for the night and there is nothing at all, no place to stay in town. Why don’t I come along with him and stay at his place?
He’s probably 4 feet tall and 75 – 80 years old and very nice to help a tall stranger in a strange land on a motorcycle of dubious tags and wearing a zippered, multi pocketed badass stereotypical moto leather jacket.
So off I go. I gather when I get to his house his wife has passed away and that he’s all alone.
Very very kind of him to share his home with me for the night.
On to Verbier.
I arrive pretty road weary and tired and take what might be my worst photo ever for the ski pass for the week, and I love it! I look pretty much like the walking dead with super helmet head and wide de focused eyes. It’s fantastic, I scan my pass and keep copies and send out copies here and there over time.
Verbier and their summer glacier. This is my first trip to it, and I’m kind of excited to see it in person after hearing so much about the snowboard summer camp and seeing all the antics in the videos.
It’s a great week, I share a lodging with a summer cool Aussie Photographer Scott Needham, and Victoria Jealouse is also in our little abode. In case you don’t know who she is, she’s a gorgeous snowboarder from Canada.
And one other Scandinavian rounds out our little comped lodging, Ami Voutailanen. These guys are basically here to shoot stills with Scott, but they’re fine to shoot video with me too.
I left after 5 days of shooting on the glacier at 6pm on July 19th.
Gas up at 8:40 pm Agip, Yverdon Les Bains, Switzerland.
Dinner back at Pontalier, France at 9:30pm.
Midnight I get into my University room in Bensancon, France.
Next day I gas up in Bayon, France, Woippy, France, and final gas stop at Rosmalen, Netherlands.
It was a really great trip.
Posted in Uncategorized by green