My '96 Rebuild - Page 4 - ZX6R Forum
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post #46 of 65 Old 08-18-2019, 01:39 PM Thread Starter
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Quick update while I wait for parts. Cleaned the garage today and have a pile of old parts with material defects that I wont be selling. I’ll try and find a recycle center that maybe buys bulk metal or something fir cheap, we’ll see. I also have a left hand fork sitting by my tools. Only thing in this pule that is not from the zx is the buell blast exhaust at the bottom (had to replace... damn vibrations!)

She’s sitting patiently for her exhaust can, coolant hose and a complete engine oil/water flush (my oil spill left me in a pinch so I had to improvise... not ideal) for new oil and engine ice (running water for now waiting on new hose).
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post #47 of 65 Old 08-25-2019, 05:43 PM Thread Starter
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Here are all the photos I have so far, should be mostly in order. Did my best to get everything but may have missed a few details. More to come.


https://drive.google.com/drive/folde...-L4SThxv068u3f

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Last edited by Brandon35; 08-25-2019 at 06:34 PM.
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post #48 of 65 Old 09-02-2019, 12:59 AM
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I did all of those things to no use, the bead on the rear would not seat fully on either side, and I could not get the front to pump up at all. Pretty sure it was the small 2gal compressor I borrowed that just couldnt do the job
The Q2's and Q3's are notoriously harder to seat the bead on than most other tires.

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post #49 of 65 Old 09-06-2019, 07:57 PM Thread Starter
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I did all of those things to no use, the bead on the rear would not seat fully on either side, and I could not get the front to pump up at all. Pretty sure it was the small 2gal compressor I borrowed that just couldnt do the job
The Q2's and Q3's are notoriously harder to seat the bead on than most other tires.
Found that out the hard way for sure. Didn't realize they had carbon fiber reinforcement but it’s a cool feature
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post #50 of 65 Old 09-09-2019, 08:18 AM
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Good work!
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post #51 of 65 Old 09-11-2019, 02:00 PM Thread Starter
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Exhaust and coolant hose FINALLY came in. What a wait that was. Anyways I have the exhaust on (sounds great with the DB Killer) and the new hose on (old one in my hand was too short). Side note I know I need to flush my system out (that was supposed to be clear water in the bottom of the pic) - am I crazy or is that a lot of dirtiness for only being in the engine for the rebuild project and a few spurts down the road? Maybe I just hadn’t cleaned out the passages quite like I thought I had? (Comparison exhaust pic added, more pics will get taken)
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post #52 of 65 Old 09-11-2019, 04:54 PM
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Likely all the scale in the radiator, and passages near the thermostat.... Tap water? Do you know how hard your tap water is?
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post #53 of 65 Old 09-11-2019, 05:43 PM Thread Starter
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Likely all the scale in the radiator, and passages near the thermostat.... Tap water? Do you know how hard your tap water is?
Thatís the thing, itís a brand new radiator AND new thermostat and i don't remember seeing anything crazy dirty inside the head when I put it in. I also used distilled water from the store, not tap water.

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post #54 of 65 Old 09-12-2019, 03:35 AM
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There's bound to be some preservative internal to the new rad. Who knows what, in the cracks and crevices of all the castings in your block. If you flush it again, the theory is you should see a lot less.

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post #55 of 65 Old 09-12-2019, 04:45 PM Thread Starter
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Going to flush the system multiple times tomorrow when i get home. I’ll keep water in it until i get my new thermostat gasket in and then i’ll take that out with all the hoses to completely drain it before i throw the engine ice in.

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post #56 of 65 Old 09-16-2019, 07:27 PM Thread Starter
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Yaaaayyyy.

https://www.zx6r.com/zx6r/114130-2nd...elp-again.html
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post #57 of 65 Old 09-16-2019, 07:43 PM
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That link gets me nowhere.
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post #58 of 65 Old 09-16-2019, 09:50 PM Thread Starter
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That link gets me nowhere.
Thatís odd, let me see

Try now https://www.zx6r.com/zx6r/114130-2nd...elp-again.html

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post #59 of 65 Old 09-18-2019, 05:53 PM Thread Starter
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Slowly working on a fix, wont really know what I can do until later this week when I start meticulously measuring all the parts. Worst case, I may buy a new 2nd gear input and output gear, get everything ISF treated and call it a day. Considering myself lucky too - I failed to realize in my reading that the piston rod bolts needed to be replaced because they stretch when torqued. Maybe that’s common sense for some of you old-timers but that was news to me.

Parts in/coming in
- New thermostat and head coolant gaskets
- all new bolts/nuts for the piston rods
- R&G exhaust sliders for the new can
- brand new, full EBC SRK clutch kit (friction plates, steel plates and heavy duty springs)

Hope to be on the right track soon - want this thing to be bullet proof. Only thing I have not done yet is a valve adjustment but I may wait till I’m out in Cali to start looking at that

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post #60 of 65 Old 09-19-2019, 01:27 AM
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Originally Posted by Brandon35 View Post
Slowly working on a fix, wont really know what I can do until later this week when I start meticulously measuring all the parts. Worst case, I may buy a new 2nd gear input and output gear, get everything ISF treated and call it a day. Considering myself lucky too - I failed to realize in my reading that the piston rod bolts needed to be replaced because they stretch when torqued. Maybe thatís common sense for some of you old-timers but that was news to me.

Parts in/coming in
- New thermostat and head coolant gaskets
- all new bolts/nuts for the piston rods
- R&G exhaust sliders for the new can
- brand new, full EBC SRK clutch kit (friction plates, steel plates and heavy duty springs)

Hope to be on the right track soon - want this thing to be bullet proof. Only thing I have not done yet is a valve adjustment but I may wait till Iím out in Cali to start looking at that

It is a hell of a lot easier to do while the engine is already out of the frame!!!!!!!

At the very least you should get exact measurements and see where they are........... No idea why you wouldn't have done that when you were doing everything else

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