The Z900 that could never be fixed is fixed at last!!!!!!!!!

[Phil50]

Well it was a year ago I tried so hard to sort this animal out and spent far too muc money and too much time.

I had some great advice from many people in here and I thank them for that.

This year I decided a new approach was required as it seemed obvious that there was more than something simple wrong here.

As you may recall it was a running rich problem with compression down even after a rebuild and rebore.

Well I took the beast to a garage/Engineer locally and said goodbye and prayed softly as I strolled off.

Well he took the top off and called me to view the mess inside.

The pistons and rings were buggered, one piston crown cracked off and the bore was glazed like a glass table top. OK I bought new genuine Kawasaki Pistons and rings and all genuine Kawasaki gaskets for the whole engine. (felt there was more to come) Left feeling sick and it was two weeks now as the pistons had to come from USA. Screw UK prices. Saved £100's.

Was called again as now another fault found in the sump. There was a slime of oil and some particles of fine sand in a sludge like formation. The residue of incorrect cleaning of the cylinder head after bead blasting by some cretins who badly advised me.

I was advised rather insisently that I get the lot cleaned as the mechanic was not going to reassemble the engine and have it do the same shit and expense again. Rather ethical I thought

Anyway I took the lot to a great little outfit in Southampton who ultrasonically cleaned the lot for 4 hours. Took the lot back to the garage and left it there.

Next problem was while the valves were being cut and faced off. Two valves slight bend not noticed by me of course and valve guides worn and splintering.

More expense but not too bad. By this time the barrels had also returned as they had to be sent to a specialist engineer for honing and crosshatching.

I had enough by now and was asked if I wanted to carry on. Like I had a fucking choice LOL. LOL.

I had gone too far and spent too much to fold my hand at this point.

So again I left without the prayer (after all what good had that done?) and went home.

stage 10 and this time it was the carbs again. Yes thats right you got it they were running rich (ebay carbs of course)So I delivered another set of carbs, ebay but from a USA biker dealers that were breaking some old Z900's and Z1000's not the private sale of "I think there ok and just need some attention (lying scum) and will probably be alright"

Ok I though this is it.

It wasn't of course.

I returned to the garage again to retrieve the carbs that were now not running on pot 3 at all. He knew I could strip them myself and probably wanted to save me some money. Well I was found the fault in twenty minutes, there was no fuel getting into pot 3 or two!! Not suprising really as they had been swapped around!!!

Can you believe this shit! I sorted them and returned them to the garage. That was wednesday. Thursday lunchtime I was phoned with two words "she's running" ahh God thank you so bloody much.

after nearly 6 weeks I have the beast back and she's running in. A bit tight of course and clutch a bit noisy as its a bit up and down under 1300 revs but pulls like a monster. Not revving over 4000 for at least 500 miles.

But last night to ride again after so bloody long was great!!! I am happy at last.

All that is now needed is the usual cosmetic touches, new indicators/glasses and stems,chrome grabrail and handlebars. a damn good polish and clean, oh and original pipes when affordable.


The moral of this little saga is a simple one and I humbly tender this advice to owners who have such problems like "running rich".

Don't just assume its the plugs or the carbs. A bike is rather like a brick wall, it needs a solid foundation to start with.

1) Get the compression checked by a competent person less than 120psi get it stripped and checked out.


2) If you get it bead balsted or vapour blasted get it ultrasonicaly cleaned after I cannot emphasise this one too much.

3) Only use genuine parts its more expensive in the long run if you don't. I did of course put the Denso plugs in and they are excellent. I have also had new cam chain and all guides as well and new rubbers all round.

4)Fitted a new oil pump. Rather lucky to get one new from USA for $30 instead of £456.00 in the UK. Why do we allow such financial rape in this country eh?

5) get the carbs Ultrqsonically cleaned too and fit all new jets and tested on a bike if possible.

6) Pass on what you have learned.


7)Here endeth the mst expensive lesson I have ever had.


Regards To all
Phil

PS have taken the plugs out three times to see if they are sooted up. they are normal. Paranoia is the norm after my last 12 months LOL LOL
byeeee

[steve rees]

Phil,

Well done---keeping it going after all that expense and uncertainty

Now a very happy zed rider

We all seem to have interesting routes while getting our bikes into good shape.

some times the most basic problem exists but is not tracked down

get some miles in now

well done

Reecy

[ollie]

like reccy said well done for carrying on ,and some great advice to others ,just enjoy yourself now .
had a sim experiencemyself and it can drive you mad ,but when you see the light at the end its damm well worth it

ollie

[Phil50]

thanks ollie

It wasn't the light I could see it was more like a red glare. I think it's called rebuild psychosis.

[ollie]

Know what you mean Phil ,it must have been a nightmare when the garage kept calling .I bet you said "what now" !!!!! and i bet he didnt want to tell you haha
ollie

[Phil50]

Actually Ollie

I said "Now what" Stolen line from the film "Deep Rising" a favourite I seem to remember they had engine problems in the film!!!!!


"Its only impossible until its done"

[ollie]

Hey close though Phil...... talking about buying from the states though ,i just bought a genuine top idler brand new for 40.00 which would have cost over double here.The prices are just mental here.

ollie

[davejames]

Hey, so pleased you got it sorted in the end Phil.

I remember your original thread that loads of us replied to, glad you persevered and didn't throw the towel in. Enjoy riding it now.

[london calling]

Really pleased for you Phil
Glad you stuck with it and got the result you deserved
I've just stripped,ultra-soniced and re-built a set of carbs,yes it's time consuming but well worth it in my opinion.They were a real mess and had several hours in the bath but are now 100% and the back on the bike. Fired up the 1000J for the first time yesterday and she's a runner

[Padders]

Hope you get some decent weather this summer so you can enjoy the bike at last Phil.

[RALPHARAMA]

Hi Phil

Sorry you had to learn so many cruel lessons, but when you're out there on sunny weekends gliding down the B roads the cost will be immaterial and when you get to rallies and meets you'll have great stories to chat about.

I had a set of carbs vapour blasted and decided that this wasn't the way forward - they were ruined.

I have decided that my bikes will never be a clean as those who've had 'em blasted but at least I'll never have an engine full of glass beads or sand My Old Gurl will never win prizes but she runs as sweet as a bag of boil sweets

[Big John]

Glad the perserverance paid off if somewhat expensive, nows the time to enjoy.

[Steve R]

Good news, thanks for letting us know the outcome, is riding slowly to run it, the way to do it, or do you risk glazing the bores again, see attached link:-

http://mailzone.onetel.net.uk/services/ ... ecrets.htm

what do others think?

[Pigford]

Phil,
Great news mate....
No Pain - No Gain...... You'll appreciate that bike so much more now
I had a decent Z1A that had a dicky starter motor a few year back.
To get the starter out, I had to remove the cam chain tensioner.
Got starter out & cleaned up the brushes...
Bunged it back on.... Thought i'd do a qiuck test to see if the started was OK.. Yes it spun over nicely
Bunged it all back together, ready for a test ride..
Ignition ON, pressed the started button.... It cranked over nice and fast, but NOTHING
Tried to kickstart it, but not a lot of compression
Where I tried the starter, but hadn't replaced the tensioner, the cam chain jumped a few teeth & bent a handful of valves

Lesson learned, so walk the 1/2 mile down to see Steve & Ray Debben & went for a new engine... Wiseco, head...etc
That ended up the thick end of £2k

BUT.... its our hobby and better than p*ssing it up againt the wall

[RALPHARAMA]

Running and engine at constant low revs is very bad for them at any state. When running in the engine mustn't be thrashed. I didn't take mine over 5000rpm whilst running in. The worst thing you can do to the engine is labour it at low revs. For the first 500miles vary the revs. After 500miles revit harder for short periods of time. Being an old fart now I have to really make my self rev the bike out from time to time, so as not to glaze the bores. When you overtake cars give the bike it's head; fats overtaking is far safer and it's good for the engine. I still haven't taken the engine anywhere near the redline, but I take her to 7000 - 7500 revs these days on over takes. I know being really gentle feels the right thing to do, but it definitely isn't being kind to the motor.

I've recently discovered, whilst getting folk to put up Z1OC SW posters, that there's a Dyno near me, so I'm going to take the Old Gurl there now she's fully run in (2500miles). It'll pain me though to hear her being revved to the red line but I'll try not to listen