Anyone in Auckland know ZZRs well?

[Unforgiven]

Is there anyone in Auckland area that knows how a ZZR goes together?

I have a 1991 ZZR400K that I got in "project" state, however as I wasn't the one that pulled it apart I'm not sure exactly how it goes back together.
I'm pretty sure that I have all the parts (and a fair few spares)
I need someone who knows these bikes well enough the re-fit carbs, air box, throttle cables, etc.
I don't mind paying them for their time.

Can anyone help?

[Akzle]

Is there anyone in Auckland area that knows how a ZZR goes together?

I have a 1991 ZZR400K that I got in "project" state, however as I wasn't the one that pulled it apart I'm not sure exactly how it goes back together.
I'm pretty sure that I have all the parts (and a fair few spares)
I need someone who knows these bikes well enough the re-fit carbs, air box, throttle cables, etc.
I don't mind paying them for their time.

Can anyone help?

i'm in auckland right now. i was going to fuck off home on monday. and i don't have tools down here. but yeah sure, giz yer bike.

[ducatilover]

ZZR600D manual will have all teh info you need.

Carbs are piss easy, slip them in to the intake boots, do intake boots up.
Reach under carbs and turn the middle throttle plate around and fit the throttle cable, taking off the velocity stack mount can help with this. You can also use long nose pliers to get them on.

Fit choke cable to top RHS of carbs.
Fit velocity stacks, run the fuel pipe and vacuum line up to the LHS of the frame so you can get 'em on the fuel tap

To fit airbox, simply put the bottom half in, there's a crank vent that it pushes in to, then there's a 10mm bolt at the rear that mounts it, and the snorkel, to the frame just above the shock.
Then, fit teh airfilter and top half of the airbox, secure the four screws and run the pipe from between carbs 2-3 on the top over the airbox through the clips.

Fit tank, hold the prime button for a while and crank it over.
It can help get started if you gently blow down the tube you run over the airbox, this forces fuel up past the needles

I think this link will work for my ZZR manual https://www.dropbox.com/home/Public/Kawasaki_ZZR600_Service_Repair_Manual let me know if it doesn't

[Unforgiven]

i'm in auckland right now. i was going to fuck off home on monday. and i don't have tools down here. but yeah sure, giz yer bike.

Damn, been out all day sorry.
When are you back in Auckland?

[Unforgiven]

ZZR600D manual will have all teh info you need.

Carbs are piss easy, slip them in to the intake boots, do intake boots up.
Reach under carbs and turn the middle throttle plate around and fit the throttle cable, taking off the velocity stack mount can help with this. You can also use long nose pliers to get them on.

Fit choke cable to top RHS of carbs.
Fit velocity stacks, run the fuel pipe and vacuum line up to the LHS of the frame so you can get 'em on the fuel tap

To fit airbox, simply put the bottom half in, there's a crank vent that it pushes in to, then there's a 10mm bolt at the rear that mounts it, and the snorkel, to the frame just above the shock.
Then, fit teh airfilter and top half of the airbox, secure the four screws and run the pipe from between carbs 2-3 on the top over the airbox through the clips.

Fit tank, hold the prime button for a while and crank it over.
It can help get started if you gently blow down the tube you run over the airbox, this forces fuel up past the needles

I think this link will work for my ZZR manual https://www.dropbox.com/home/Public/Kawasaki_ZZR600_Service_Repair_Manual let me know if it doesn't

The carbs aren't the hard part, the problem is that Im not even sure of whats there and whats missing.

[Phreak]

Google search for a workshop manual, easiest way to figure out if it's all there or not. It's not that complicated! If you do get stuck even with a manual, I may be able to help you out in the weekends, depending on my work. Feel free to PM me if you get to that stage. :)

[Akzle]

Damn, been out all day sorry.
When are you back in Auckland?

not if i can help it. (but probably some time next month)

my ute shat it's shit, so it's going to get a bit of love from some cunt with a surface grinder.

TBH, if you can't pick what should be inside a bike, why did you buy a project?!?!

[Unforgiven]

TBH, if you can't pick what should be inside a bike, why did you buy a project?!?!

I can probably get it together with the manual, its just far easier to get someone who has seen it in one piece before to see if its all there.
If I had taken it apart it wouldn't be a problem (although Im far better with injected engines than carbies)
Or maybe I'm just being lazy :o

[ducatilover]

TBH, if you can't pick what should be inside a bike, why did you buy a project?!?!

Because one would never learn otherwise? You silly green fellow :bleh:

[Akzle]

I can probably get it together with the manual, its just far easier to get someone who has seen it in one piece before to see if its all there.
If I had taken it apart it wouldn't be a problem (although Im far better with injected engines than carbies)
Or maybe I'm just being lazy :o
yeah. lazy. but i get ya. slap it together (it'll probably only fit one way) and then it'll either work. or not, but you'll be no worse off.

Because one would never learn otherwise? You silly green fellow :bleh:
yeah, but as he said, if he'd taken it apart in the first place... he wouldn't be in this conundrum.

[Unforgiven]

This is the current state of the bike:
282154282153282152282150282151282155

[Laava]

Mate, do yourself a favour and join a kawasaki forum, and make sure you enjoy putting it back together. Looks pretty complete and should be a POP if the motor is a goodun!

[ducatilover]

Seems to have all the important bits there :niceone:
Join zzr-international.co.uk, there's a heap of knowledge on there

How much did it set you back, if you don't mind me asking? My 400k set me back $800, supposedly just a stuffed clutch, but it turned out it was slowly eating itself inside... :laugh:
I have a full set of new clutch fibres somewhere for one actually.

[Unforgiven]

Anyone know what this is and where/how it goes?
http://i587.photobucket.com/albums/ss311/Unforgiven_59/101_2921_zps64769ad8.jpg
http://i587.photobucket.com/albums/ss311/Unforgiven_59/101_2920_zps21c2ba44.jpg

[ducatilover]

My 400k or 600D haven't got anything with that on the end, but it looks like the carb bowl vent with something attached.
Have you got vent pipes on the connections on top of the carbs?

Otherwise it goes on to the intake boots

[Unforgiven]

Where is the best place in AKL to take the bike to get it worked on?

So far its just endless frustration, I cant even be sure I have all the right parts
I cant fit the carbs without connecting the throttle cables, I cant be sure which way around to connect them as the other end is in bits as well.

If I continue I have a 50/50 chance of having to start all over again :Pokey:
Its driving me nuts, I have all the info and 90% of the gear to fully rebuild the whole engine but I cant get info on the simplest things :weird:

[Pumba]

George at Mr Doctors. Best bit is he will come to you.

[ducatilover]

You only need one cable, the pull cable. Hook it up at the handle bar and just use the one.

Bring it to Tauranga and I'll sort it :bleh: