Go Back   Motorcycle Forum > Motorcycle.Com General Discussion > Motorcycle Mods and Maintenance

Thread Tools
Old 07-29-2008, 09:13 AM   #1
Registered Member
Join Date: Jul 2008
Posts: 1
Default 96 kaw rebuild - timing, valves & bearing HELP

I got a 1996 ZL600 from a guy that put a connecting arm through the case and then let it sit for 8 years. I rebuilt the motor and it is running, but it sound bad. This is the first time I've rebuilt a motor so I'm not sure if I got the timing wrong, or if I need a valve adjustment or if I put the wrong bearings around the shaft.

I wonder about the timing because when I aligned the timing mark on the case, The pistons (1 & 4) were TDC just before the timing marks were aligned as I turned the shaft clockwise. When the timing marks were perfectly aligned, the pistons were just past TDC. What I mean by this is the pistons went up and were just starting their way back down when the timing marks were aligned. I'm not sure this is right, but I went with it because the marks were aligned and I figured that was the thing to do.

from the right side of the motor, I lined up the cam shafts and counted the links (42) from exit to inlet mark and then torqued everything to spec.

I didn't make any adjustments to the vales as I didn't see any need because i didn't take them apart.

As for the crank shaft bearings, I picked the "black" set rather than the blue or brown based on shaft and case marking. I didn't use any plastigage to verify I just figured the marking were good enough.

It turns on and idles at 1100 rmp per spec, it just makes a clicking/clattering noise when I rev the motor.

To figure this out I made myself a stethoscope from a rubber tube and a coat hanger so I could listen to the motor. the top doesn't sound bad, not major clacking noise. The piston cylinder doesn't sound bad, the bottom of the motor does have a pining sound several times a second. I don't hear any difference as I move along the bottom of the motor from left to right.

I've taken it to the shop and one place told me I need a valve adjustment. Another place told me I have the wrong bearings. It is so much trouble to take the motor apart especially if I need to get to the bearing, so I want to be sure before I move forward.

Does anyone out there have any advice or comments?
bsc is offline   Reply With Quote

Sponsored Links Remove Advertisements
Motorcycle Forum
Old 07-29-2008, 09:22 AM   #2
Super Duper Mod Man

longride's Avatar
Join Date: Nov 2001
Location: Anywhere they let me
Posts: 10,479

"Does anyone out there have any advice or comments?"

I do. Stop wasting your time and money on the piece of crap and go get something that runs.
I'm a knucklehead
longride is offline   Reply With Quote
Old 07-29-2008, 09:33 AM   #3
Women Riders Moderator
sachiwilson's Avatar
Join Date: Jun 2007
Location: San Diego
Posts: 1,609


Honey, we can give reasonable advice on things like gummed up carbs, but your questions are WAY beyond what someone on the internet can answer. Sorry.
Frappé LaRue
*Safety Queen*
Are you a Rounder?

Sarnali: "what could be more useless than arguing with a deaf female lawyer????"
sachiwilson is offline   Reply With Quote

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

vB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off