ZX7R Problem. {meltdown pic added}

timmyrocks · Post by **timmyrocks** » Wed Jul 08, 2009 8:23 pm

haha i know what you mean mate, my bikes have been there many of times before

. you will be amazed at how much you learn though and the fulfilment in knowing whats on the bike and how to confidently work and troubleshoot on it

all part of the fun, keep us updated on the trial n error

gpxpunk · Post by **gpxpunk** » Wed Jul 08, 2009 11:29 pm

oh i will. When i bought my gpx, i had no idea. but i have stripped it a half dozen times now and know every little thing. {had it in pieces this after noon}
So now i just need to get the work shoot manual for the 7 to know every little detail.

But yeah ill keep you all posted.

Frank · Post by **Frank** » Thu Jul 09, 2009 1:32 pm

gpxpunk wrote:oh i will. When i bought my gpx, i had no idea. but i have stripped it a half dozen times now and know every little thing. {had it in pieces this after noon}
So now i just need to get the work shoot manual for the 7 to know every little detail.

But yeah ill keep you all posted.

hey mate

If you want to swing past my place at Rooty Hill on afternoon I can give a copy of the ZX7R manual on disc.

gpxpunk · Post by **gpxpunk** » Thu Jul 09, 2009 4:50 pm

frl0173 wrote:
gpxpunk wrote:oh i will. When i bought my gpx, i had no idea. but i have stripped it a half dozen times now and know every little thing. {had it in pieces this after noon}
So now i just need to get the work shoot manual for the 7 to know every little detail.

But yeah ill keep you all posted.

hey mate

If you want to swing past my place at Rooty Hill on afternoon I can give a copy of the ZX7R manual on disc.

cheers dude, could swing past anytime. i work at arndell park so just cruze through.

gpxpunk · Post by **gpxpunk** » Sat Jul 11, 2009 12:11 pm

kawasaki250 wrote:yer pop the caps off the solenoid and get a screw drive and touch both of them, dont be afraid of the sparks . do this before you take to starter off. this will totally bypass all the safety switches and ignition

ok tried this and nothing, still the spinning noise.

Removed the starter motor and then pushed the start button and nothing no spin.

timmyrocks · Post by **timmyrocks** » Sat Jul 11, 2009 3:49 pm

do you know if the starters a throw out, i.e is the starter constantly spinnining with the engine, or when you start it does it get thown out to turn the flywheel over????
robs right on this one find a new starter

Gav · Post by **Gav** » Sat Jul 11, 2009 4:32 pm

Geez mate, I hope everything works out for the best,,

gpxpunk · Post by **gpxpunk** » Sat Jul 11, 2009 5:20 pm

kawasaki250 wrote:do you know if the starters a throw out, i.e is the starter constantly spinnining with the engine, or when you start it does it get thown out to turn the flywheel over????
robs right on this one find a new starter

Ok Joe just left, we have worked out a few things and eliminated a few aswell.
1. Dont need a new starter motor
2. not the gear box
3. not the engine.

Haha, rob you might be right. Looks like the starter clutch. problem is looks like i have to crack the case to get to it. lol bit more work to go. But atleast i will get it all nice and cleaned and running the way i want it to run.
Thanks Joe for helping me out today.

gpxpunk · Post by **gpxpunk** » Sun Jul 12, 2009 4:13 pm

snorky wrote:Geez mate, I hope everything works out for the best,,

its getting there slowly. just need to get some more parts and tools and should be sweet. All my alenkeys are shit. so got to get a better set since i cant get the outter clutch hub off. Hey Joe thanks for the special tool, I got the nut off after abit of swearing, just didnt use the extension bar on the socket.
Had a look through the work shop maual joe brought over and it says to check the starter clutch by checking the idle gear by hand. now its says the gear should not turn anti-clockwise but clockwise. So i ripped the starter off and yes doesnt turn anti-clockwise by it does go the right way.
Also removed the magneto cover and can turn the crank, which inturn turns the outter clutch basket. but it will turn till a certain point then stops. if you turn it the other way it still turns but then stops a the same certain spot.

So! so far i just need to get the outter clutch hub off to get to everything behind it, see whats wrong. if it is the starter clutch then i have to crack the bloody case. hope it isnt that bad but as i said b4 it might be. thanks Rob.

And cheers Joe.

gpxpunk · Post by **gpxpunk** » Sun Jul 26, 2009 5:05 pm

ok engine is out and ready for the mechanincs tomorrow. hopefully nothing expensive. but then again i dont care. i just want it fixed

waynemorgan · Post by **waynemorgan** » Sun Jul 26, 2009 7:42 pm

Well done mate - hope you get it back soon and without much $$ pain.

gpxpunk · Post by **gpxpunk** » Sun Jul 26, 2009 8:34 pm

waynemorgan wrote:Well done mate - hope you get it back soon and without much $$ pain.

dont worry wayne, that makes both of us!!

now all i need is the indicators and the engine to start and ill have to start on the fairings, But thats the easy part.

have to dig up joe's paint code and go get some paint.

So kwaka green, gloss black, and maybe white if i cant be bothered getting stickers.

Oh and clear, but i might use 2 pac for that.

gpxpunk · Post by **gpxpunk** » Thu Jul 30, 2009 5:26 pm

ok, well picking up engine tomorrow from kelens. Not the best result i wanted but im not pissed, i was expecting it.

Firsitly, No its not the starter clutch, all good there.
Oil stinks. And i mean stinks. the internal oil filter has melted, allowing alot fo shit to wonder around the engine.
Alll the bottom end seams to be fine. The cam chain is black as and will need to hopefully be cleaned if not replaced.{see how i go}

Priced a top end to see if it would be cheaper and metro's have one but charging $1500 for it. AHH NO!

So I think a complete rebuild is in order haha as kelens said. THis would be best.

They also said it would be good to pull the gear box apart and make sure no gunk is in there. looks all clean but ill see how good i am lol.

Worse case scenario is buying a 2nd engine. mmm will be hard unless some one has on cheap for me?????

waynemorgan · Post by **waynemorgan** » Thu Jul 30, 2009 5:46 pm

Damn Dave - full rebuild?

You have 94 days....your time starts now!

Let me know if I can help in any way - don't know much but have some well hidden muscles somewhere here......

gpxpunk · Post by **gpxpunk** » Thu Jul 30, 2009 5:54 pm

lol thanks dude, yeah not a total rebuild mmm maybe i have no idea really.
All i know is it has shit all the way through the engine and i need to clean it all. There might be something stuck in the cam chain that is stopping it from turning.

A vavle might be stuck.

The previous owner should be farken shot to let a zx7r get like this. But as i said alot of the engine looks good, clean and in good condition its just the top end so far that is shit.

When i went in the back of kelens the sump was off and could see the gearbox and bottom of the cam chain {black as anything}.

so ill pick it up tomorrow, get it home and see what i can sart after doing the valves on the gpx250.

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ZX7R Problem. {meltdown pic added}

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