Mella yella (zxr400) rebuild.

[F5 Dave]

True racing machines are so much easier. Getting the shock out of the 750 put me off for so long. The GasGas on the other hand looked just as hard then I realised you just unbolt the rear subframe mounts (just to bottom ones if you are lazy) , loosen the carb connection & rotate the back end out of the way exposing the shock.

Ahh bliss!

[Blakamin]

yeh tell me about it, just spent since 7:30am installing a new Half system + muffler for my racebike... had to take the shock out and front radiators off (well, swinging) and what a friggin mission! again...

And whats stupid is i dont have time to do the same to my street bike as its got the best shock - and my racebike despite having halfway been there has to stay with the shit shock (6 preload settings, no remote res, and its pogo like damping).

So close... And more bad news? i just realised the system i got was a bloody standerd half system with a hacksawed off muffler and aftermarket/homemade muffler put on... ohh damnit!.. worse again? my last system was from the later model NC35 standerd system which gives better midrange!!!

SO WHAT THE HELL AM I DOING?!
man this is so damn infuriating.

Trial and Error is my way of life.

Are you going to put the old system back on?

how come you didn't notice till now???

[Kwaka-Kid]

i did actually... but like i said im all about trial and error, i have only tried the NC35 system on my race vfr, and the NC35 system with my chop and modification and home made can, and ive tried the NC30 system on street vfr, and chopped version iwth anohter made can...
so now i guess time to try NC30 system on my racebike, with a different again muffler/dimensions. maybe the dude in aussie was into something? doubt it but still.. apparently the NC35 system just gives a slightly better midrange with no difference top end between the 2. and also the NC30 system im putting on gives slightly more gorund clearance... last round at taupo i put it down on the left and side and hooked the exhaust pipe where its under/on the left side of the bike! lifted what weight was left on the rear end and sent me rear wheel drifting. lucky nothing happend it just came back together as i stood it upright a little, but i dont want to do that too often and it nearly put a hole thru the pipe.

[Blakamin]

Lets hope you find a combination that works!... glad I've only got the one set! just taking my pipes off drives me nuts!

[Jay widda 150]

anyone want a blowen rg150 engine to rebuild only $5.

[F5 Dave]

Let me guess, dropped powervalve. Oh well roll it up the road to Buckets.

[FROSTY:Me]

to round up this thread I got mella yella finished at the pits at pukekohe.
The motor is now run in and seems to be making good power.
With all the outwork needed and a fairly decent list of parts I think the total is going to come in at about $1500. Sounds a lot but I think we have built a strong reliable motor .
Now I need to focus on my ground clearance and suspension.

[That Guy]

Phewie - just reading about all this valve graind work and shims and dollars and stuff......maybe my ol'd 2 smoker ain't so bad!

[gav]

So are you going to dyno it, Frosty?

[FROSTY:Me]

So are you going to dyno it, Frosty?

I'll sort out the other stuff first. It seems to be running well so I wont muck around with it.I'll get the next round sorted out

[FROSTY:Me]

After my piss poor showing at Taupo I had to do some serious reevaluation
I need to work on my riding and get more track time but If I wanna compete with the SV650's on an even playing feild then I need to find a fair bit more HP and loose weight.
Yep I'm getting serious now.
The first and most odvious job is to measure fuel consumption. Up till now I've been keeping the tank fairly fullish which means lugging around 20 odd litres of gas and all the weight that entailds. I'll be running a much lighter fuel load.
The flywheel has now had the big chop which hopefully will mean she will get up the revs easily off the line.
Ive been running an O ring chain but thats getting the bin treatment and a lighter chain is going on.
The rear subframe is getting chopped off just behind the seat -I wass going to make a new subframe up but the ally is pretty light weight.
The wiring loom is getting the big strip down treatment and all onnnecasary wires are getting the chop. Makes fixing it easier too
I've ordered the 444kit from the UK through Gary at GP spares--top bloke that. Ill get the spare barrells bored out and keep the standards Just in case
Ive got the Olins rear shock on its way th Hawera Motorcycles to be set up for the 400
Gary Has a Dynajet kit for me so I have adjustable needles to suit different tracks
The CDI box is going in the bin and being replaced with a remappable version from ER and D -With carefull remapping im asured that rather than 4 power spikes like it is now I should get a smooth lineer (sp) power delivery.
Im going to stick with the dunlops because so far I have only had one scare on em -and that was scrubbing the first set in.
Ill be plucking the ignition switch out and and extra seals on wheel bearings etc. The aim is to get a 15% power increase that is usable which should get the power within reach of the SV650's
Im hoping that the next time me and SVS pull onto the straight he wont just grunt his bike away into the distance.

[Kwaka-Kid]

SERIOUS!

sheesh, Frosty dude give me some of your lotto winnings! Your bike will be god, nice plans though dude if i had the money available for spending on the beast id be doin all that too, what about some nice big flat slide pumper mechanical carbs on her?

[FROSTY:Me]

Was going down the flat slide track but Ill need some serious track time in order to jet em right for the zxr-all the other work is gonna be -bolt it on and go.
KK I guess its all relative--I did think of selling mella yella and buying a sv but like MY finished all up including the cost of the bike will be less than 6k whereas a SV will cost me 11 k then it still needs suspension work-$1500 then a pipe etc--Mella yella looks to be the cheapest option

[Redstar]

After my last outing at Pukie it seemed Mella yella had got a tadd sick.
Before stripping him down for a rebuild I thought I'd better do a baseline run to see just how bad he is.
After 2 runs on a local dyno I thought the hp test was for someone elses bike. 41 then 42 hp seems a tadd low.
Alex did a compression test for me.
In theory he shouldn't be running it seems. Worst compression is in number 2 at a big 50psi compression.
The others are better but right at the bottom end of the range for a bike to run on.
It seems one of my oil rings has sucked the kumera as well as 3-yes 3 valves bent
Origonally I planned on boring him out to 420cc but I figure now that just a rebore to max oversize a valve grind and replacing the bent valves will be enough to freshen him up.
I still need to sort out the rear shock but It might be a case of borrow the olins out of my zxr750

Mate I can speak with a bit of authority here the ZXR400 can pull 65Hp if unrestricted and fully kitted 42hp is nowhere near the bikes target performance what are you on about?

[FROSTY:Me]

Mate I can speak with a bit of authority here the ZXR400 can pull 65Hp if unrestricted and fully kitted 42hp is nowhere near the bikes target performance what are you on about?

That was my point exactly redstar-It was performing very badly -Basicly had sucked a kumera -Either in a previous life or more likely due to a couple of MAJOR overrevs by me at pukie there were issues with valves etc.
Second time the performance dropped off it was down to piss poor reassembly work and 2 carb intake rubbers had pulled away inwards--One worse than the other -so the bike was sucking in gobs of air instead of fuel
Thats all fixed now and shes back to normalish