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 Post subject: Engine failure....
PostPosted: Sun Oct 08, 2017 9:23 pm 
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Moto GP Rider
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Joined: Wed Apr 27, 2011 5:50 pm
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Location: Wigan
Not a ZX9,but a ZZR1400.
Bought as a non runner for something to do over the coming winter months.

Check out these pics... :shock: :shock:

The Cam sprockets have ...erm..fallen off.. !!

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This has resulted in the cam chain snapping with the resultant valve damage...

Amazingly the bottom end is fine,just a scratch where the valves hit the crown of the pistons.
What looks like has happened is that sometime in the past,the bike has had its shims done and the cam sprockets have been seperated from the cams.No threadlock used and this is the result.
I cant even find 3 of the bolts.The 4th was snapped and in the head.
So much for full history ....... Not worth the paper its written on.


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20171007_202834.jpg
20171007_202834.jpg [ 552.19 KiB | Viewed 166 times ]

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 Post subject: Re: Engine failure....
PostPosted: Sun Oct 08, 2017 9:49 pm 
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BSB Rider
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Location: Canada F1
yeah that's amazing there wasn't more damage from it.

The pic doesn't show it, is the cam chain broken?


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 Post subject: Re: Engine failure....
PostPosted: Sun Oct 08, 2017 10:02 pm 
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Moto GP Rider
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johny9r wrote:

The pic doesn't show it, is the cam chain broken?



Yep,violently snapped in half :D .The guides will also need replacing.
Collets on a couple of valves pushed up out of the holding grooves...

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20171007_203816.jpg
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 Post subject: Re: Engine failure....
PostPosted: Sun Oct 08, 2017 11:51 pm 
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WSB Rider
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Joined: Mon Jul 13, 2015 2:53 am
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Location: BRISTOL zx9r B2
Nice project to take on


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 Post subject: Re: Engine failure....
PostPosted: Mon Oct 09, 2017 10:25 am 
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Location: Manchester
Very lucky indeed ,

would be doing my head in as to where the bolts have ended up :? :?

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 Post subject: Re: Engine failure....
PostPosted: Mon Oct 09, 2017 10:50 am 
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Moto GP Rider
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Steve-TC1 wrote:
Very lucky indeed ,

would be doing my head in as to where the bolts have ended up :? :?


Probably in the mechanics pocket who shimmed it :lol:

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 Post subject: Re: Engine failure....
PostPosted: Mon Oct 09, 2017 4:49 pm 
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Ukbikenut wrote:
Steve-TC1 wrote:
Very lucky indeed ,

would be doing my head in as to where the bolts have ended up :? :?


Probably in the mechanics pocket who shimmed it :lol:

:lol: ive done that, got home and thought whats in my pocket oh just some really important looking bolts. Oh well just put them in the spares draw with the other 30,000 ive collected over the years


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 Post subject: Re: Engine failure....
PostPosted: Mon Oct 09, 2017 6:11 pm 
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Moto GP Rider
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streak198507 wrote:
Ukbikenut wrote:
Steve-TC1 wrote:
Very lucky indeed ,

would be doing my head in as to where the bolts have ended up :? :?


Probably in the mechanics pocket who shimmed it :lol:

:lol: ive done that, got home and thought whats in my pocket oh just some really important looking bolts. Oh well just put them in the spares draw with the other 30,000 ive collected over the years


Haha ,i view it as a minor miracle if i end up with no leftover parts :lol:

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 Post subject: Re: Engine failure....
PostPosted: Tue Oct 10, 2017 10:37 am 
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Moto GP Rider
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Absolutely commendable effort...but not a full house as 2 survived,so no prizes :D


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 Post subject: Re: Engine failure....
PostPosted: Tue Oct 10, 2017 1:23 pm 
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Privateer
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Location: 9R,2001,E2...Croatia
Question;
Could there be any damage to the crankshaft considering that valves hit pistons and that impact force has been transfered through connecting rods all the way down to the crankshaft ? :-k


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 Post subject: Re: Engine failure....
PostPosted: Tue Oct 10, 2017 2:09 pm 
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Moto GP Rider
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Im in the process of taking the bottom end off as we speak.I highly doubt it,but better to be 100% sure for just a little bit more work.Im more concerned about finding a cracked/broken piston skirt tbh.

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 Post subject: Re: Engine failure....
PostPosted: Tue Oct 10, 2017 8:25 pm 
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WSB Rider
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Location: pickering north yorkshire 2002 zx9r e2
be a good project that, be interesting to see how it goes bet original owner was gutted


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 Post subject: Re: Engine failure....
PostPosted: Fri Oct 13, 2017 11:12 am 
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Moto GP Rider
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daveh wrote:
bet original owner was gutted


Hes a tw@t....!!!

The bottom end has been inspected and as i suspected is completely unscathed.Piston skirts are fine.
I think the sheer size and robustness of the crank and journals have saved the day here,even the pistons,though very short are heavily braced underneath.In comparison the valve stems are positively puny in comparison.
For a 35k mile bike there is NO discernible wear anywhere on the motor.Bores still have the cross hatching,no lip whatsoever,cam lobes are spot on.The only discernible wear i can find is on the exhaust valve guides,where there is a tiny amount of play.
Next stage is to decide how to progress.
Edit...i found the remains of 2 other snapped bolts from the cam sprockets,in the sump.Making the total number to 3.There is no sign of the 4th bolt,it isnt there unless its vapourised.

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 Post subject: Re: Engine failure....
PostPosted: Sun Oct 15, 2017 10:07 am 
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Joined: Fri May 05, 2006 12:47 am
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Location: Manchester
What size are the valves , I have a spare E head here

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 Post subject: Re: Engine failure....
PostPosted: Sun Oct 15, 2017 3:09 pm 
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Moto GP Rider
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Location: Wigan
Wouldn`t fit Steve,intakes are considerably larger.
Wont be buying a new set of valves thats for sure(£40 for a valve),so its a good second hand head job,quite a few for sale over the pond,but the customs charges are a bit steep.So gonna hold out for a UK one.

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