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2004-20-23 636
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Well if the outside of that tank is fine and it’s just the inside and not rusted through bad you can 100% fix that. Just a good cleaning and de rusting process and a really good tank coating and you should be set.
Just follow the instructions on the coating to a t. Takes a bit of time you need to turn the tank every so often to get it run down and coating the whole thing. I usually just set one up in the morning and every 30 minutes or so rotate it and position it differently. Koats makes a good one. I personally use the POR15 brand. I have alwasy got good results from it.
And for cleaning the rust get you a couple gallons of vinegar and CLR . First try and shake and blow all the bigger flakes and junk out. Then fill with vinegar and clr I do about 3 part’s vinegar and 1 part CLR for the first pass. Fill about 3/4 full. Then add some sharp rocks or even bolts. A good hand full. Seal the cap and bottom so it doesn’t leak out as bad. Shake the crap out of it. Pour and repeat. If it’s super bad I usually do this a couple times then for the last use mostly the CLR. Once you get all the flakey rust and chunks let it dry completely. Blow air. Sit in sun whatever just needs to be bone dry. Then start the coating process. And you are good to go

The first tank I ever done was a 50”s Harley I restored and it actually had some pin holes where gas would leak. I was really not wanting to ruin the patina so I just did the process above and the coating actually sealed the pin holes. I’m 45 now I did that Harley in my late teens and it’s still 100% sealed and filter has always been clean. The good thing about coating is once you coat it then you never have to worry about future rusting. So if it’s good when you finish chances are very good you will never have to address it again.

you can get CLR about anywhere. Stands for calcium lime rust remover. Hardware store Wallmart prob. Lowe’s. Anyplace like that.
 

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1986 ZX600
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23 Posts
Discussion Starter · #23 ·
I just tore the crankcase down got the external shift stuff off and found why it doesn't want to shift. The shift linkage I guess idk the splined thing that goes into the crank case is cracked and broke away from the crank case. I was wondering if this was repairable or if I could replace just the lower crack case with the transmission and would I have to do anything extra.
Motor vehicle Automotive tire Bicycle part Vehicle brake Rim
 

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1986 ZX600
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Discussion Starter · #25 ·
Can I just replace that section of the case or do should I replace the entire case and use what I can from the old one. But yeah it's definitely a bummer but overall just a minor setback I was aiming for late April to have it running but probably mid May now at best but stuff happens we grow from it. It's my first bike and first time tinkering with them so I'm learning a lot from it along the way and prbly doing a lot better then most people my age.
 

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The transmission may be okay…. Kawasaki has employed a‘positive neutral finder’ for quite some time. It may only go into first or neutral at a stop if so equipped. I don’t recall if the ‘86 had that.
It did, it dates back to the late 70's
 
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Well I owned about 6 of these back in the 80's and also had an 88' variant (basically same engine, basically)that I ran to 256,000 miles........

and I do indeed have a stockpile of parts still for these
rod and main bearings, most all the engine gaskets and seals, I believe a set of wiseco pistons
another head or 6 and a couple sets of carbs in unknown currently condition
 
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Dang bro. That sucks. Need a case more than likely . A good machine shop that tigs could possibly repair it. Must of seized up and someone was racking on the shifter trying to get it to move. Bummer.
more likely was crashed on the shifter.this would not be the first one I saw break off- it is not well supported

good welder and some machining is going to be the best imo............ unless

and I did not read much of the thread.........

unless you need extensive engine stuff, then perhaps a donor engine form a junkyard would be the way to go
 
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1986 ZX600
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Discussion Starter · #29 ·
more likely was crashed on the shifter.this would not be the first one I saw break off- it is not well supported

good welder and some machining is going to be the best imo............ unless

and I did not read much of the thread.........

unless you need extensive engine stuff, then perhaps a donor engine form a junkyard would be the way to go
I think the majority of the engine except the head and the lower crankcase I can reuse. I just need to find those and then get all the gaskets and rings and I should be into reassembly.
 

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I think the majority of the engine except the head and the lower crankcase I can reuse. I just need to find those and then get all the gaskets and rings and I should be into reassembly.
What is wrong with the cylinder head?

and The crankcase set is a set, you either replace both halves as a set or you replace neither.......... I would opt for the weld it up and machine the hole to fit again route.....
(why...... becasue if you buy another set of cases with a different engine number, then you have to go to the dmv and change it on the title and here in Minneshithole they make you jump through 8gajillion hoops to do so....under the guise of stopping motorcycle theft and engine theft..... but really it is just another revenue stream for them to piss away on stupid assfuck bullshit
 
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1986 ZX600
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Discussion Starter · #32 ·
What is wrong with the cylinder head?

and The crankcase set is a set, you either replace both halves as a set or you replace neither.......... I would opt for the weld it up and machine the hole to fit again route.....
(why...... becasue if you buy another set of cases with a different engine number, then you have to go to the dmv and change it on the title and here in Minneshithole they make you jump through 8gajillion hoops to do so....under the guise of stopping motorcycle theft and engine theft..... but really it is just another revenue stream for them to piss away on stupid assfuck bullshit
The 2 of the cam caps are damaged and it is cheaper for me to buy another head and have it decked then it is to buy new caps and have them line honed and bored to match wear on the cams. I'll definitely look into getting it welded up then.
 

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I’d go the cam caps route. Being this thing is so old I’d use what I have. Instead of Finding a head this old and dealing with what problems that may have. Unless you just luck up and find a reputable person to deal with.
 

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1986 ZX600
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Discussion Starter · #34 ·
I’d go the cam caps route. Being this thing is so old I’d use what I have. Instead of Finding a head this old and dealing with what problems that may have. Unless you just luck up and find a reputable person to deal with.
I would but one of the caps that the valve cover bolts into is trash and the top of it is destroyed from previous owners siliconging a smaller diameter bolt in.
 

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What condition are the rockers arms in?
they had a propensity to wear out and then take the cams with due to assfucks of stupid adjusting the split fork rocker incorrectly or just never adjusting them........or running them low on oil or or or........
 

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Discussion Starter · #39 ·
What condition are the rockers arms in?
they had a propensity to wear out and then take the cams with due to assfucks of stupid adjusting the split fork rocker incorrectly or just never adjusting them........or running them low on oil or or or........
They seemed ok with the quick look over I gave them I didn't check against specs or anything because I just plan on replacing the head due to the damaged cap.
 
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