Got a new to me bike

Sounds like valve train noise to me, or potentially something jammed in the piston top hitting the combustion chamber at TDC?

You are taking it out anyway for the 2nd gear fix. Get it on the bench and verify all the valve clearances are correct before you dis-assemble it. Hopefully you'll find one or two way loose and be able to correct it with out much trouble.

Tony

 

Yes, engine will def come out. Hopefully this weekend. Trying to locate an engine gasket set at the moment.
Was looking for the diagram to find the "adjusting screws/lock nuts with a single rocker actuating two valves" that you mentioned. Haven't been able to find the correct one yet (and manual is in my garage).

 

Here's the valvetrain view link from Babbits:
https://www.kawasakipartshouse.com/oemparts/a/kaw/50a98901f8700218fcc090f8/valve-s

And a Japanese source from E-bay on the gasket set:
https://www.ebay.com/itm/85-96-KAWA...969019?hash=item2111d31d3b:g:tCcAAOSwmtJXakGE
(Bought the FZR1000 gasket set and carb kits for the FZX Mikunis from them: Good Stuff BTW)

Tony

 

Ah ok.
Your diagram is a different year. Didn't see that for a 94. Maybe that's why.
Thanks for the eBay link.
I also sent an email to Babbitt's and bikebandit as I like buying from them, easier with returns too

 

Crap, sorry about that, thought it was a 96? 600R not the ZX-6.
And that engine looks to be shim under bucket like the Maxim X:
https://www.kawasakipartshouse.com/oemparts/a/kaw/500b230af8700223e478b6ed/valve-s

Either way, just verify all the clearances before dis-assembly.

Tony

 

Yes sir, will check before disassembly.
And yes, under bucket just like the FZR.
In case they are the same, I'll definitely reach out to you. If I remember correctly you are running a shim pool for those.

 

Shims under bucket, well good thing you are pulling the engine. I guess once you do it and get past the not knowing jitters, doing those type are not bad. My first go at it was interesting but then once you get how to line up the cams, chain and screw them down, it is okay.

 

Yes, did it twice on FZR engines. Did it with engine in bike. A bit of a pain and nerve wrecking because you don't want to drop stuff into the engine. This one will be easier.

 

Well, not running a shim pool, but do have extras from all the engines I've done.
Dave has some too, but believe only for the Yamaha's.

Much easier with the engine out for sure. Some shim kits are offered by Wiseco and Hot Cams, but not sure if they are compatible for that engine.

Tony

 

Guess I'm dropping the forks completely as well and will check how straight they are.
Wanted to remove fender but it's wedged in there, even though it should slide out.

 

Fabricated my own little engine stand. Will slide underneath. The stand allows my to gently lower it.
Tony, yes, the engine will come out.
The stand is right by swingarm. As long as the swingarm pivot bolt is not going through the engine I'm golden. And there are a few inches room between engine and stand cross beam.

Probably want to put forks back in and secure front. Not sure if bike tips on way or the other when engine is out as the weight will shift.

 

Tony, yes, the brake lines will be replaced.
The front brake pistons need to be replaced as well. So far the worst part of the bike...

 

Good thing, and those calipers are pretty crusty.

BTW, nice engine stand.

Tony

 

Engine should be ready to drop in a few. Just going over everything to make sure everything is disconnected. As well as making sure bike doesn't tip backwards on stand.

 

Man, so much work to get this this...
Nice thing with stand is that I lifted frame right off. Engine "stand" worked perfectly.
Wife keeps calling and is pissed, need to stop work now. Anywho, I accomplished what I wanted to do.
Worst part so far: getting the rear axle out, believe it or not.

 

Not quite sure what's going on there. Only took pic, didn't inspect further

 

that is the bump stop in the case where the shock bottoms out.
I found the same type of deterioration on my 88 FZ600. I wouldn't worry too much about it.

 

Ok cool.

Happy with the progress today.
I'll take wheels for tire change next Saturday. By then I should have the rest of the bike cleaned, my new rear fender put on and the fork springs replaced and back on the bike. So hopefully next Saturday I have a clean and complete roller and I can focus on engine, which would be the last piece.
Oh yeah, the front brake calipers need some lovin. Will get the pistons out this week as well and order parts.

 

An hour of detailing and half way through tail section.


Plus rear fender replaced

 

Cleaning done.



Now need to figure out how to depress the fork caps to get snap rings out. I'm not heavy enough it seems. Guess I have to put them back into bike. This way I don't compress springs.

Also ordered misc parts like rubber bands, o rings, banjo bolts etc