JoelP
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| posted on 26/2/06 at 11:29 AM |
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fitting a zx9
hello all.
(Its a zx9c by the way  )
Im starting working through the loom today, to make sure ive understood it and have all the bits i need. In the picture below, i think top left if the
CDI, top right is the reg/rec, bottom left is a fuse box and bottom right is a spare box, if memory serves its not off a zx9. Can anyone confirm these
parts? Cheers.
 
Rescued attachment bec 001.JPG
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JoelP
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| posted on 26/2/06 at 11:30 AM |
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also, ISTR that these parts can overheat when fitted. Is it worth putting a fan on either the cdi or the regulator? Or just put it in the airflow.
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Spin8Spin
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| posted on 26/2/06 at 12:42 PM |
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The cdi, fuse box and reg/rec are as you said but i haven't got the box in the bottom right on my zx9 c
Matt
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Tangerine Scream
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| posted on 26/2/06 at 12:44 PM |
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From your picture I have all but the bottom right unit on my car so the spare unit could well be off another bike.
The rectifier unit does get warm, but I've mounted it in a place where it'll get reasonable airflow. The ECU/CDI unit doesn't seem
to get warm at all.
HTH
Steve
PS Nice engine choice BTW :-)
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JoelP
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| posted on 26/2/06 at 01:04 PM |
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i noticed a few more bits im missing Ive got no fuel pump relay, then again, my car already has a bike pump fitted so i might not change the
fueling.
no clocks, not the end of the world for now. It will run without them though, wont it?
Is the fan switch in the radiator? Might just use my existing rad then.
Speedo sender, is this on the engine? Ive found the plug on the loom but no sign of where it plugs in.
There is no clutch cable, just the hole beside the oil filler hole. Where do i get one and how does it all connect?!
Do you use both throttle cables or just one? Extra springs maybe?
How the hell do you get the sprocket off?! Ive tried impact wrench and normal wrench, but it just spins when in gear. Im thinking i need a chain to
hold it still.
Sorry for all the questions guys Any ideas?
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Tangerine Scream
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| posted on 26/2/06 at 01:24 PM |
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My car starts and runs without clocks (as I stupidly found out when tracing wires with the battery still connected - doh!)
I have no cooling fan. Plumbed as per Ben Marriott's diagram with a cortina rad, it has never overheated, even with prolonged stationary
periods.
Speedo sensor takes a feed from a sensor just above the sprocket. Using hall effect of the sprocket bolts, it still works when a sprocket adaptor is
in place. The signal, fed through a yellowbox can be calibrated correctly for the bike clocks.
The hole by the oil filler cap should contain a clutch lever arm that actuates the clutch. I have a set of engine drawings that I can send you if you
like.
I used only one throttle cable. the second one (to close the throttles) was replaced by a external spring at the carb end. On their own the normal
carb springs weren't man enough to shut the throttle quick enough.
I had no sprocket on my engine. I would think that if it was in gear it shouldn't be spinning that easily?
HTH
Steve
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Spin8Spin
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| posted on 26/2/06 at 01:28 PM |
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engine does run without the clocks.
fan switch is in the rad.
the speedo sender is in a cover around the front spocket but this weill have to come off to fit the sprocket adapter.
as for the cables i haven't got that far yet i just have a bit of string as my throttle.
getting the front spocket off took me absolutly ages i eventually did it with a 4 foot metal pole with 2 m8 bolts through it with nuts along the
length of the bolt (m8 nuts fit the shape of the sprocket teeth very well) and then slotted it on to the sprocket to stop it turning, then hoped i
could still fit a socket on the nut. (not the best of descriptions, think i've still got it somewhere so can take a photo if u need it)
Matt
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zilspeed
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| posted on 26/2/06 at 01:30 PM |
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Makes sure it's in 1st gear - the gearing will assist you in getting the sprocket nut loosened.
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Mad Dave
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| posted on 26/2/06 at 02:08 PM |
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If you are going to use the bike clocks I have some in the workshop that are looking for new home
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JoelP
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| posted on 26/2/06 at 03:09 PM |
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dave, u2u on its way
cheers for the tips everyone else. The bar with bolts seems best so far - in gear it turns the full engine over, even with the impact wrench (which i
feel bad using). Thats with the lock tab folded back too.
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Wadders
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| posted on 26/2/06 at 03:28 PM |
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Existing bike fuel pump will be ok.
Yes it will run without clocks.
I use micra rad switch, works fine.
Speedo sender is mounted in sprocket cover, you have to make a bracket for it..
Clutch should have a lever/operating arm fitted into the hole (dont panic i have a spare one)
One throttle cable works fine
Removing sprocket with engine out is fun, but persevere it is possible.
If i was you i'd buy some uprated clutch springs and fit them while its easy to work on. (only about £20)
Originally posted by JoelP
i noticed a few more bits im missing Ive got no fuel pump relay, then again, my car already has a bike pump fitted so i might not change the
fueling.
no clocks, not the end of the world for now. It will run without them though, wont it?
Is the fan switch in the radiator? Might just use my existing rad then.
Speedo sender, is this on the engine? Ive found the plug on the loom but no sign of where it plugs in.
There is no clutch cable, just the hole beside the oil filler hole. Where do i get one and how does it all connect?!
Do you use both throttle cables or just one? Extra springs maybe?
How the hell do you get the sprocket off?! Ive tried impact wrench and normal wrench, but it just spins when in gear. Im thinking i need a chain to
hold it still.
Sorry for all the questions guys Any ideas?
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JoelP
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| posted on 26/2/06 at 03:34 PM |
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quote:
Originally posted by Wadders
If i was you i'd buy some uprated clutch springs and fit them while its easy to work on. (only about £20)
That sounds like good advice, but its just another daunting task to do - ive never done any work inside engines/clutches/gearboxes before. How
hard?
My engine has no lever for the clutch, in fact, neither does! How much to part you with your spare alan?
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Andy W
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| posted on 26/2/06 at 05:51 PM |
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Don't bother with EBC springs they are worse than standard. Get barnett ones, I've had no problems with them
Andy
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G.Man
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| posted on 26/2/06 at 05:59 PM |
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quote:
Originally posted by Andy W
Don't bother with EBC springs they are worse than standard. Get barnett ones, I've had no problems with them
Andy
That applies to the EBC plates as well
Opinions are like backsides..
Everyone has one, nobody wants to hear it and only other peoples stink!
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Wadders
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| posted on 26/2/06 at 06:27 PM |
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Don't panic Joel, they're dead easy to change, just remove the clutch cover, and then swap them one by one, each one is held in by a 6mm
bolt. As for the clutch lever, buy me a pint and its yours!
That sounds like good advice, but its just another daunting task to do - ive never done any work inside engines/clutches/gearboxes before. How
hard?
My engine has no lever for the clutch, in fact, neither does! How much to part you with your spare alan?
[Edited on 26/2/06 by Wadders]
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JoelP
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| posted on 26/2/06 at 08:47 PM |
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cheers Al! Stick it in ya van, next time you pass marks just leave it with him, you can choose between a pint (or two!) or a drive at teesside if i
get it finished!
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Wadders
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| posted on 26/2/06 at 10:20 PM |
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No problem, this might also be of interest
http://www.ppcmag.co.uk/forum/topic.asp?TOPIC_ID=1028
Originally posted by JoelP
cheers Al! Stick it in ya van, next time you pass marks just leave it with him, you can choose between a pint (or two!) or a drive at teesside if i
get it finished!
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JoelP
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| posted on 27/2/06 at 08:41 AM |
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cheers again, i was trying to remember the name of his site!
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mackei23b
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| posted on 27/2/06 at 01:38 PM |
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Hi there
Loks like the fuse box of a ZX(R B series), box on the bottom left of picture
Cheers
Ian
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JoelP
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| posted on 27/2/06 at 05:49 PM |
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cheers mate.
ive now ordered the sprocket adapter. Just wondering what i should use for a clutch cable? I found a lever on the other engine, which is annoying -
means that neither engine is totally compete and i'll have to arrange bits.
Theres two pipes that come up between the carbs and join. Anyone know what these are? The fuel pipes are underneath.
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Mad Dave
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| posted on 27/2/06 at 05:55 PM |
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quote:
Theres two pipes that come up between the carbs and join. Anyone know what these are? The fuel pipes are underneath
Do you mean the carb heaters?
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zxrlocost
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| posted on 27/2/06 at 06:09 PM |
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and if your doing the clutch dont forget a new clutch cover gasket '
worth the £10
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JoelP
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| posted on 27/2/06 at 06:50 PM |
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carb heater it might well be, do i keep or ditch?!
Damn, more gaskets... that paper is annoying stuff! Gonna order some barnett springs so i guess i'll have to get a new gasket.
cheers chaps!
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kipper
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| posted on 27/2/06 at 07:26 PM |
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Avatar
Hi JoeLP.
Can you change your avatar? I think it's that that's atracting the white stuff falling here.
Think sunshine
Regards Kipper.
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JoelP
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| posted on 27/2/06 at 07:30 PM |
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you're right, out with the white, in with the red
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