handyandy24 Posted November 7, 2009 Share Posted November 7, 2009 QuestionDo the camshafts need to be removed from the cylinder head in order to access the bolts which will allow the head to come away from the main block. The Haynes section on this is poor. It kind of skips the Cylinder head cover removal and illustrations are poor. I know there are some ZZR lovers here. Any help would be greatAndy Quote Link to comment Share on other sites More sharing options...
Guest Posted November 7, 2009 Share Posted November 7, 2009 you would need to remove the cam-chain to remove the head.. so i would think so... here is a diagram, from the looks of this the bolts (B),© are between the camshafts... use this as a source for exploded diagrams...http://www.cmsnl.com/kawasaki-1990-c1-z ... partslist/ Quote Link to comment Share on other sites More sharing options...
handyandy24 Posted November 7, 2009 Author Share Posted November 7, 2009 Thanks. From the looks + haynes there are 10 bolts that go down into the body. You can get at 4 of them but te other 4 are half underneath one of the camshafts:(Thanks for the link should be usefull Quote Link to comment Share on other sites More sharing options...
Guest Posted November 7, 2009 Share Posted November 7, 2009 if you look at the gasket there is a bolt on each side of the pistons = 10, and to get at would need the cams out... just be sure to lay everything out and put bits together that should be together, i'e no1 valve with spring, and no2 with bits, etc, etc, makes it easier on re-assembly.. Quote Link to comment Share on other sites More sharing options...
Stu Posted November 7, 2009 Share Posted November 7, 2009 just remove the cams its only a two minute job and would make things a bit easier but then you would have to remove them anyway to release the cam chain Quote Link to comment Share on other sites More sharing options...
handyandy24 Posted November 8, 2009 Author Share Posted November 8, 2009 havent had to remove the valves +springs. removed the cams. cam chain, tensioner and such. taken the head off now exposing the pistons. the engine running has a knock he thought it was from left side no1 little end moving from side to side. unfortuantely on inspection there is nothing obiously wrong with any of the pistons, gudgion (spelling) seem ok. Job for another day though is removing and examining them. Any obvious things to look for? Quote Link to comment Share on other sites More sharing options...
Guest Posted November 8, 2009 Share Posted November 8, 2009 i would have checked everything externally before removing the head, like exhaust headers, and anything bolted on.... one of the guys on here was chasing a noise and it turned out to be an exhaust clamp under the bike..... Quote Link to comment Share on other sites More sharing options...
handyandy24 Posted November 9, 2009 Author Share Posted November 9, 2009 Dont worry the obvious was checked before the head was removed!!!!!! Any hints on what to look for re.faulty piston Quote Link to comment Share on other sites More sharing options...
Guest Posted November 9, 2009 Share Posted November 9, 2009 Dont worry the obvious was checked before the head was removed!!!!!! Any hints on what to look for re.faulty piston scoring of the cylinder bore and/or bust rings would be the obvious choice.. colour/soot another.. also irregular movement of the conrod.. sure its not a bust valve?? Quote Link to comment Share on other sites More sharing options...
handyandy24 Posted December 19, 2009 Author Share Posted December 19, 2009 I am now trying to put the top of the engine back over the pistons. ie. get the pistons back in the barrels. This is proving tricky, Ive been told this is a fiddly time consuming exercise but does any1 have any tips, first time ive done it so dont have a nak for it yet. At the mo we are packing under the pistons with a rag to keep them stable and trying to compress the rings one at a time with our hands to get the pistons in the barrels when we lower the head back on. any tips would be greatandy Quote Link to comment Share on other sites More sharing options...
cyberwolf Posted December 19, 2009 Share Posted December 19, 2009 see if any of this helps Haynes Manual translations Haynes: Rotate anticlockwise. Translation: Clamp with molegrips then beat repeatedly with hammer anticlockwise. Haynes: This is a snug fit. Translation: Clamp with molegrips then beat repeatedly with hammer. Haynes: This is a tight fit. Translation: Clamp with molegrips then beat repeatedly with a hammer. Haynes: As described in Chapter 7... Translation: That'll teach you not to read through before you start. Now you are looking at scary photos of the inside of a gearbox. Haynes: Pry... Translation: Hammer a screwdriver into... Haynes: Undo... Translation: Go buy a tin of WD40 (giant economy size). Haynes: Retain tiny spring... Translation: PINGGGG - "Jesus, where the hell did that go?" Haynes: Press and rotate to remove bulb... Translation: OK - that's the glass bit off, now fetch some good pliers dig out the bayonet part (and maybe a plaster or two). Haynes: Lightly... Translation: Start off lightly and build up till the veins on your forehead are throbbing then clamp with molegrips then beat repeatedly with hammer. Haynes: Weekly checks... Translation: If it isn't broken don't fix it. Haynes: Routine maintenance... Translation: If it isn't broken, it's about to be. We warned. Haynes: One spanner rating. Translation: An infant could do this... so how did you manage to **** it up? Haynes: Two spanner rating. Translation: Now you may think that you can do this because two is a low, teensy weensy number... but you also thought the wiring diagram was a map of the Tokyo underground (in fact that would have been more use to you). Haynes: Three spanner rating. Translation: Make sure you won't need your motorbike/car for a couple of days. Haynes: Four spanner rating. Translation: You're not seriously considering this are you? Haynes: Five spanner rating. Translation: OK - but don't ever carry your loved ones in/on it again. Haynes: If not, you can fabricate your own special tool like this... Translation: Hahahahahahahahahahahahahahahahahahahahahahaha. Haynes: Compress... Translation: Squeeze with all your might, jump up and down on it, throw it at the garage wall, then find some molegrips and a hammer... Haynes: Inspect... Translation: Squint at it really hard and pretend you know what you are looking at, then declare in a loud knowing voice to your wife/husband/partner "Yep, as I thought, it's going to need a new one" Haynes: Carefully... Translation: You are about to suffer deep abrasions. Haynes: Retaining nut... Translation: Yes, that's it, that big spherical blob of rust. Haynes: Get an assistant... Translation: Prepare to humiliate yourself in front of someone you know. Haynes: Turning the engine will be easier with the spark plugs removed. Translation: However, starting the engine afterwards will be much harder. Once that sinking pit of your stomach feeling has subsided, you can start to feel deeply ashamed as you gingerly refit the spark plugs. Haynes: Refitting is the reverse sequence to removal. Translation: Yeah, right. But you swear in different places. Haynes: Prise away plastic locating pegs... Translation: Snap off... Haynes: Using a suitable drift... Translation: Clamp with molegrips then beat repeatedly with hammer. Haynes: Everyday toolkit Translation: RAC Card & Mobile Phone Haynes: Apply moderate heat... Translation: Unless you have a blast furnace, don't bother. Alternatively, clamp with molegrips then beat repeatedly with hammer. Haynes: Index Translation: List of all the things in the book, bar what you need to do. Quote Link to comment Share on other sites More sharing options...
Guest Posted December 19, 2009 Share Posted December 19, 2009 you need at least 2 piston ring clamps and a mate... one of you lowers the head the other offers up 2 pistons, then offer up the other 2, piston ring clamps compress the rings to enable them to slide into the bore. Quote Link to comment Share on other sites More sharing options...
Guest Posted December 19, 2009 Share Posted December 19, 2009 see if any of this helps Haynes Manual translations Haynes: Rotate anticlockwise. Translation: Clamp with molegrips then beat repeatedly with hammer anticlockwise. Haynes: This is a snug fit. Translation: Clamp with molegrips then beat repeatedly with hammer. Haynes: This is a tight fit. Translation: Clamp with molegrips then beat repeatedly with a hammer. Haynes: As described in Chapter 7... Translation: That'll teach you not to read through before you start. Now you are looking at scary photos of the inside of a gearbox. Haynes: Pry... Translation: Hammer a screwdriver into... Haynes: Undo... Translation: Go buy a tin of WD40 (giant economy size). Haynes: Retain tiny spring... Translation: PINGGGG - "Jesus, where the hell did that go?" Haynes: Press and rotate to remove bulb... Translation: OK - that's the glass bit off, now fetch some good pliers dig out the bayonet part (and maybe a plaster or two). Haynes: Lightly... Translation: Start off lightly and build up till the veins on your forehead are throbbing then clamp with molegrips then beat repeatedly with hammer. Haynes: Weekly checks... Translation: If it isn't broken don't fix it. Haynes: Routine maintenance... Translation: If it isn't broken, it's about to be. We warned. Haynes: One spanner rating. Translation: An infant could do this... so how did you manage to **** it up? Haynes: Two spanner rating. Translation: Now you may think that you can do this because two is a low, teensy weensy number... but you also thought the wiring diagram was a map of the Tokyo underground (in fact that would have been more use to you). Haynes: Three spanner rating. Translation: Make sure you won't need your motorbike/car for a couple of days. Haynes: Four spanner rating. Translation: You're not seriously considering this are you? Haynes: Five spanner rating. Translation: OK - but don't ever carry your loved ones in/on it again. Haynes: If not, you can fabricate your own special tool like this... Translation: Hahahahahahahahahahahahahahahahahahahahahahaha. Haynes: Compress... Translation: Squeeze with all your might, jump up and down on it, throw it at the garage wall, then find some molegrips and a hammer... Haynes: Inspect... Translation: Squint at it really hard and pretend you know what you are looking at, then declare in a loud knowing voice to your wife/husband/partner "Yep, as I thought, it's going to need a new one" Haynes: Carefully... Translation: You are about to suffer deep abrasions. Haynes: Retaining nut... Translation: Yes, that's it, that big spherical blob of rust. Haynes: Get an assistant... Translation: Prepare to humiliate yourself in front of someone you know. Haynes: Turning the engine will be easier with the spark plugs removed. Translation: However, starting the engine afterwards will be much harder. Once that sinking pit of your stomach feeling has subsided, you can start to feel deeply ashamed as you gingerly refit the spark plugs. Haynes: Refitting is the reverse sequence to removal. Translation: Yeah, right. But you swear in different places. Haynes: Prise away plastic locating pegs... Translation: Snap off... Haynes: Using a suitable drift... Translation: Clamp with molegrips then beat repeatedly with hammer. Haynes: Everyday toolkit Translation: RAC Card & Mobile Phone Haynes: Apply moderate heat... Translation: Unless you have a blast furnace, don't bother. Alternatively, clamp with molegrips then beat repeatedly with hammer. Haynes: Index Translation: List of all the things in the book, bar what you need to do. :laugh: Thats so true! haha Quote Link to comment Share on other sites More sharing options...
Guest Posted December 19, 2009 Share Posted December 19, 2009 Cyberwolf/Chris, I don't think your post helps this thread and might be better in entertainment/humour.. it just clutters this one up. Quote Link to comment Share on other sites More sharing options...
Mightycaz Posted December 19, 2009 Share Posted December 19, 2009 Clutters yes, but also makes me laugh!!Handyandy where in Chester are you based? And er, to keep it on topic, Did you fix it? Quote Link to comment Share on other sites More sharing options...
handyandy24 Posted December 20, 2009 Author Share Posted December 20, 2009 Thanks WalkneyHadnt spotted those on ebay, just the ones which dont open out fully and therefore be trapped on the rod. Have purchased 2 and will give it a go next weekend. Hopefully can get it done as this is messing up our momentum a bit. Mightycaz I live in north wales on the way to the ponderosa. Close to the liver in if you know it. Ill be lucky to get out to work tomzThanks for the help ill let you know how we get onandy Quote Link to comment Share on other sites More sharing options...
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