handyandy24 Posted January 18, 2009 Posted January 18, 2009 hey dudes, more zzr problems..grr..had to get a snapped mounting bolt drilled out and all is ready. got them gaskets in that compress when you tighten the pipes in. my problem is when we try to put the pipes on they go over the holes. i then hold it in place while the father tries to put the mounting brackets (made up name) over the bolts. My problem is both wont go on together even tho without the exhaust in place they go over fine. we have tried jigging the pipes around a bit as we do it incase the pipes arent angled correctly but no luck. its like the brackets arent going on flush which is why i think it cud be the angle of the pipes. or maybe the pipes arent 'in'enough as the gaskets arent compressed enough to allow the brackets to travel far enough up the bolt to come together flush. Any thoughts? This could be a zzr specific problem. TimR ? :D:D Quote
Guest Posted January 18, 2009 Posted January 18, 2009 confused by the post sorry not sure which bit you on about http://www.cornwallkawasaki.co.uk/shop/ ... am&id=2695can you pin point which bit where etc using that then can have a ponder Quote
Stu Posted January 18, 2009 Posted January 18, 2009 if its the metal ring gaskets that go in the engine block where the pipes slot in then try tapping them home with a suitibly sized socket Quote
handyandy24 Posted January 18, 2009 Author Posted January 18, 2009 hmm yes after re reading my post i concur haha.At the very end of the pipes (that go into engine block) you can see the brackets which the studs go through.On this ZZR the brackets (im calling them that as dont know the name) are not attached to the pipes. They come in 2 parts, so in total you have eight, 2 per pipe. I put the pipes in place. Then I try to place the 'bracket' over the studs and then add washer + bolt. My problem is I can get one side of the 'bracket' on fine but then the other half isnt in line so it wont complete the bracket as a whole and hold the pipes in place.I had originally thought this was possibly due to the gaskets being new in are not allowing the pipes to rest as deep as they usually would, and maybe because of this the 'bracket' can slide down the studs as much as they need to (maybe need to be right down before go on flush). Im unsure.As far as I know my dad has just greased the gaskets that go in the block. Do they need hammering in, or is it just a case of faffing and jigging the pipes around until they are at the perfect angle which will allow the 'bracket' to fit perfectly? Thought id ask rather than waste another hour getting annoyed when there maybe some trick im missing Hope this is easier to follow lol Quote
Guest Posted January 18, 2009 Posted January 18, 2009 in all honesty i have no idea only things i can think of i take it that this is not a genuine exhuast but an aftermarket one have you tried swapping the bracket pieces about , back to front etc this exhaust is specifically for that model zzr ?and from what i remember the zzr has stubs on the manifold ( exhaust to engine joint) so that the gasket sits on this stub and the stubs then sit into the ports and the gaskets are normally as stu has said compression rings ( small metal rings)so sadly i cannot give you a definte answer ..... Quote
Guest Posted January 19, 2009 Posted January 19, 2009 if you bolting up one side and then another you will cause the part to not sit level, so this may be your problemtry just attaching one nut then the other, so the whole thing is held loosely in place and then tightening in succession, so that you bring it up a bit at a time.. (like you would to adjust a chain) turning each nut one turn then moving on to another so think of them as numbers 1 - 81 , 2, 5, 6, 3, 4, 7, 8, and again, you can do more turns as you feel but if you fully tighten one side then the others gonna be sat out..as you bring it in it should compress your gaskets.. Quote
handyandy24 Posted January 21, 2009 Author Posted January 21, 2009 "and from what i remember the zzr has stubs on the manifold ( exhaust to engine joint) so that the gasket sits on this stub and the stubs then sit into the ports and the gasketS"im not sure what you mean by this. The exhaust is an aftermarket one, witha single can, its a 4 into 1. had the sam eprob with a genuine one tho.ive tried swapping the brackets around and tightening it a bit at a time. the gaskets have just been put in the hole in the engine where the downpipes go.the studs stick out away from the engine Quote
Guest Posted January 21, 2009 Posted January 21, 2009 looking into the manifold is there a seat for the gaskets or are they flat?looking into the engine from the exhaust ports is there a seat here to?if yes to both, then you need to get the gaskets to sit here ..where did you get the gaskets? are they right for your model? Quote
Guest Posted January 21, 2009 Posted January 21, 2009 http://www.speednspares.co.uk/acatalog/ZZR600.jpgif ypu look at pic you can see the manifiold "brackets" are fixed with a stub that goes into the port that the gasket will sit on.. if you have the original exhaust still or the old one compare and measure it up side by side Quote
handyandy24 Posted January 21, 2009 Author Posted January 21, 2009 id assume my dad bought the gaskets for his model, im not sure tho just helping him out. I havent looked inside the engine to see how the gaskets sit or into the manifold for the same reason. ill have a look asap. thanks guys! Quote
Guest Posted January 21, 2009 Posted January 21, 2009 http://www.cmsnl.com/kawasaki-1989-c2-z ... E1140.htmlhere is an exploded diag of the exhaust..just wondering, have the old gaskets been removed? this could be that the two gaskets are trying to fill one hole..if so can you compare the two together, are they similar?you may find that putting the gaskets in the seat then pushing them home with a soft mallet and piece of wood, helps.... also stops the buggers falling out...the ZX600 (ZZR) has two types of exhaust gasket the manifold to cylinder head 11009A and muffler to muffler 11009. Quote
Guest Posted January 21, 2009 Posted January 21, 2009 if its aftermarket it might not require parts 92027, check the instructions supplied with the manifold? Quote
handyandy24 Posted January 21, 2009 Author Posted January 21, 2009 well the problem does seem to be that the manifold doesnt go in enough making the brackets not go over the studs fully. hes just put them in hes just told me. ill have a look at the weekend Quote
handyandy24 Posted January 21, 2009 Author Posted January 21, 2009 i wish i had instructions haha. that may be the problem, ive got a little checklist of things to investigate im sure it will be one of em. thanks lads Quote
Guest Posted January 21, 2009 Posted January 21, 2009 http://www.motorcyclenews.com/MCN/advic ... &R=EPI-665How to by MCNsee para 5 Quote
handyandy24 Posted January 21, 2009 Author Posted January 21, 2009 you mean the fiddling around part? my dads taking me sat morning to a computer fair in manchester, and in return in the afternoon im helping him fit the exhaust. so i guess its all afternoon rite up until tea at 7 Quote
handyandy24 Posted January 23, 2009 Author Posted January 23, 2009 dad back from working away this week. he didnt think it neccesary to mention earlier over the phone that 5 of the 8 studs are shorter than the originals . gona try get me hands on some actual zzr studs and hopefully that will solve the problem Quote
Guest Posted January 23, 2009 Posted January 23, 2009 92004066 STUD,6X27 x 8 = £20http://www.cmsnl.com/kawasaki-1989-c2-z ... E1111.htmlYou'll need a stud extractor Too, Check model, above, this is a guide.. Quote
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