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Old Streetfighter Motorcycle Forum Post 09-13-2017, 03:57 PM   #1
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Question Engine Rebuild, Honing and piston ring question?!

Hey all,

I am rebuilding my 1987 Kawasaki ZX600-A3 (GPZ600) due to low compression mainly in middle two cylinders (4 Cylinder Jap engine) and I need to Hone the cylinders and install new piston rings.... Can I get away with standard size piston rings on the standard piston ? i believe this is the engine's first rebuild so a quick hone to clean up the cylinder's shouldnt cause too much of an issue right ? theres no deep scratches or scores, this is my first engine rebuild and im not exactly knowledgeable or experienced in this area. also what else should i replace/clean or do while the engine is apart ? looking for all the help i can get :P .

Thanks in advance!
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Old Streetfighter Motorcycle Forum Post 09-13-2017, 06:01 PM   #2
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Default Re: Engine Rebuild, Honing and piston ring question?!

If you're reusing the stock pistons you have to use the same size stock rings. You only need larger rings when you use larger pistons
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Old Streetfighter Motorcycle Forum Post 09-13-2017, 09:37 PM   #3
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Default Re: Engine Rebuild, Honing and piston ring question?!

Obviously replace the base, head, and valve cover gaskets, along with any o-rings you have access to, like the oil pipe in the head and the external oil pipe on the front of the head.

Other things to check are valve clearances, camshaft lobes, cam chain and tensioner, chain guides, spark plugs and gap...

If they haven't been replaced, I'd change the carb holders (16065-1129) because they are cheap and they tend to harden with age and can crack and cause problems.

If you are ordering a lot of OE parts, I've found http://www.partzilla.com/ to have some of the best prices on OEM parts.

I think the piston rings on these bikes need to be installed in a particular order and I'm pretty sure the top rings have a side that points up.
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Old Streetfighter Motorcycle Forum Post 09-14-2017, 08:00 AM   #4
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Default Re: Engine Rebuild, Honing and piston ring question?!

Quote:
Originally Posted by Larry02ACR View Post
Obviously replace the base, head, and valve cover gaskets, along with any o-rings you have access to, like the oil pipe in the head and the external oil pipe on the front of the head.

Other things to check are valve clearances, camshaft lobes, cam chain and tensioner, chain guides, spark plugs and gap...

If they haven't been replaced, I'd change the carb holders (16065-1129) because they are cheap and they tend to harden with age and can crack and cause problems.

If you are ordering a lot of OE parts, I've found http://www.partzilla.com/ to have some of the best prices on OEM parts.

I think the piston rings on these bikes need to be installed in a particular order and I'm pretty sure the top rings have a side that points up.








Nice one Larry! Repped!
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Old Streetfighter Motorcycle Forum Post 09-14-2017, 12:11 PM   #5
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Default Re: Engine Rebuild, Honing and piston ring question?!

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Originally Posted by shinyribs View Post
If you're reusing the stock pistons you have to use the same size stock rings. You only need larger rings when you use larger pistons
Thanks shinyribs, ill keep that in mind!
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Old Streetfighter Motorcycle Forum Post 09-14-2017, 12:13 PM   #6
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Default Re: Engine Rebuild, Honing and piston ring question?!

Quote:
Originally Posted by Larry02ACR View Post
Obviously replace the base, head, and valve cover gaskets, along with any o-rings you have access to, like the oil pipe in the head and the external oil pipe on the front of the head.

Other things to check are valve clearances, camshaft lobes, cam chain and tensioner, chain guides, spark plugs and gap...

If they haven't been replaced, I'd change the carb holders (16065-1129) because they are cheap and they tend to harden with age and can crack and cause problems.

If you are ordering a lot of OE parts, I've found http://www.partzilla.com/ to have some of the best prices on OEM parts.

I think the piston rings on these bikes need to be installed in a particular order and I'm pretty sure the top rings have a side that points up.

That is the most perfect response I could have ever hoped for! you absolute legend! Thankyou so much for that in depth response man much appreciated!
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Old Streetfighter Motorcycle Forum Post 09-14-2017, 01:02 PM   #7
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Default Re: Engine Rebuild, Honing and piston ring question?!

Also! how can you tell if you need to replace the valve springs ?
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Old Streetfighter Motorcycle Forum Post 09-14-2017, 02:21 PM   #8
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Default Re: Engine Rebuild, Honing and piston ring question?!

Somewhere in the book there should be a minimum/maximum amount of tolerance for valve springs.

Most measurements look like this, can also have the procedure call for it to be off the head too, been forever since I've been in a early ZX6 engine so I'm not sure what the book calls for in this case.




You can also check them for squareness too.




There is also a test for compression of the spring rate too.





When my brother and I were working on a ZX6A we found extremely worn valves, so make sure to inspect the valve faces as well, the ones in the old ZX6A were worn so bad they had an edge on them that could cut paper.







Found some old pics too. Fresh engines are so sexy.






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Old Streetfighter Motorcycle Forum Post 09-14-2017, 05:01 PM   #9
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Default Re: Engine Rebuild, Honing and piston ring question?!

Quote:
Originally Posted by RatFighter View Post
Somewhere in the book there should be a minimum/maximum amount of tolerance for valve springs.

Most measurements look like this, can also have the procedure call for it to be off the head too, been forever since I've been in a early ZX6 engine so I'm not sure what the book calls for in this case.




You can also check them for squareness too.




There is also a test for compression of the spring rate too.





When my brother and I were working on a ZX6A we found extremely worn valves, so make sure to inspect the valve faces as well, the ones in the old ZX6A were worn so bad they had an edge on them that could cut paper.







Found some old pics too. Fresh engines are so sexy.
Thanks RatFighter, A very detailed and helpful response! Sorry about all the questions im just worried about my first engine rebuild haha dont know what im getting myself into XD I have just ordered a new Haynes manual as I somehow lost my old one ... oops haha so hopefully that will shed some light on dimensions and tolerances but thankyou again! you guys are awesome!
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Old Streetfighter Motorcycle Forum Post 09-14-2017, 09:33 PM   #10
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Default Re: Engine Rebuild, Honing and piston ring question?!

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Originally Posted by CK 187 View Post
Repped!
Tell me again how I can trade these rep points for beer?
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