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Old 10-14-2013, 05:05 PM   #1
DJFlowe OP
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Probably in over my head (1990 ZX 7)

Well, I'm probably in way over my head here. It's long been a goal of mine to tear a bike down to bare frame/bare block and start over.

Enter this Craigslist special: 1990 ZX 7. Listing said the guy had bought it to ride, but found out it needed a full carb rebuild and he wasn't interested in doing the work. He'd had it listed for a while, and was willing to deliver for a very reasonable price. I jumped.

I've never done anything this ambitious- I hope this is a good learning experience and keeps me busy over the winter. I'm very open to any feedback or advice you folks have to share....

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Old 10-14-2013, 05:08 PM   #2
kraven
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find a 2nd rack of carbs off ebay or something and rebuild those. Swap the two racks out to minimize downtime and forgetfulness about what goes where and how and why.

Replace all the fuel lines with injection rated line to withstand the ethanol included fuels. All of 'em.

Buy rebuild kits from Keyster or through the Kawi dealer.
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Old 10-14-2013, 05:13 PM   #3
DJFlowe OP
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Initial Teardown

My goal for the first day was to get the bodywork off and get a good look at exactly what I was working with.

It's good that the carbs are in a box, right?


Chain is clean enough to eat off of.


As is the tank:


One of the PO's dropped the forks several inches in the triple trees.

The result is that the front end was so low, the headers got beat half to death. Anyone know if I can re-use this header in this condition, or will I have to replace it?
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Old 10-14-2013, 05:18 PM   #4
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Cappuccino anyone?


And how 'bout this coolant?


Is the stock coolant cap from a malt liquor bottle?


Does anyone know what this is?


Shock linkage looks pretty rough...
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Old 10-14-2013, 05:21 PM   #5
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To my surprise, the bike has been extensively safety wired. Wonder if it was just tracked quite a bit, or if it was actually raced at some point?







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Old 10-14-2013, 05:23 PM   #6
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Quote:
Originally Posted by kraven View Post
find a 2nd rack of carbs off ebay or something and rebuild those. Swap the two racks out to minimize downtime and forgetfulness about what goes where and how and why.

Replace all the fuel lines with injection rated line to withstand the ethanol included fuels. All of 'em.

Buy rebuild kits from Keyster or through the Kawi dealer.
Thanks, Kraven. Will do on all- I think starting with an assembled set of carbs would make the project a lot simpler anyway.
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Old 10-14-2013, 05:36 PM   #7
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that's concerning.

Need to figure out if that's coolant in the oil and oil in the coolant.

Probably need to pull the water pump and see if it's shit the bed or puked the o-ring or something, or if you have a problem around the head gasket or elsewhere.
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Old 10-14-2013, 05:40 PM   #8
DJFlowe OP
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Something somewhere's not good. I'm planning on doing a full rebuild, so I hope that the issue that led to this makes itself known. And yes- that's definitely oil in coolant and coolant in oil.
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Old 10-14-2013, 05:53 PM   #9
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Steering damper mount.
There should be a threaded lug on the frame for the other end.


Quote:
Originally Posted by DJFlowe View Post
Does anyone know what this is?
[URL=http://s634.photobucket.com/user/djflowe_2009/media/ZX7%20Teardown%201/IMG_1157.jpg.html]
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Old 10-14-2013, 05:54 PM   #10
skwidd
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Do a compression test before you dig too far, make sure it's worth fixing and not better suited as a planterbox in the yard.
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Old 10-14-2013, 06:02 PM   #11
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Originally Posted by skwidd View Post
Do a compression test before you dig too far, make sure it's worth fixing and not better suited as a planterbox in the yard.
This is a first for me, so please forgive if this is a stupid question.

My plan is to tear it all the way down, replace all piston rings, gaskets and seals, etc. If I'm going to do that anyway, will the compression test tell me anything?
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Old 10-14-2013, 06:13 PM   #12
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I hope you didn't pay much over $300 for that thing.
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Old 10-14-2013, 06:15 PM   #13
OConnor
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Many of those ~90 Zx7s (and GSXRs) were club-raced. I had a '91 gixxer similar to your Kaw. I should have walked away when I noticed the safety wire. Most of those old war-horses were put to pasture by selling them to punks that will never change the oil never mind coolant or brake fluid or spark plugs (or they did and you'll find the stripped threads to prove it).


Bottom line: As much fun as old school sport-bike archeology is, this project will get real expensive, real fast.
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Old 10-14-2013, 06:56 PM   #14
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Quote:
Originally Posted by OConnor View Post
Many of those ~90 Zx7s (and GSXRs) were club-raced. I had a '91 gixxer similar to your Kaw. I should have walked away when I noticed the safety wire. Most of those old war-horses were put to pasture by selling them to punks that will never change the oil never mind coolant or brake fluid or spark plugs (or they did and you'll find the stripped threads to prove it).


Bottom line: As much fun as old school sport-bike archeology is, this project will get real expensive, real fast.
That's probably what I'm working with. It looks to have been worked hard and then parked in someone's yard after being lowered.

I've got next to nothing in it. Probably stick through the tear-down and if it's repairable I'll get it back on the road. If not, I'll fleabay the parts to finance the next pandora's box of a bike I can find....
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Old 10-14-2013, 07:06 PM   #15
rocker59
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Quote:
Originally Posted by DJFlowe View Post
Well, I'm probably in way over my head here.

Craigslist special: 1990 ZX 7.

Quoted for posterity.
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