Checked the water level this morning and there is about 250ml missing from the expansion tank. Took the rad cap off and I have mayo.
No water in the oil, but definately some oil in the water. Engine is a ZZR1100.
I have a run out planned for tomorrow, a track day on 20th April and a Fucking Big Blat round Scotland in May.
What to do?
1. Bung some K-Seal in it today and see how it holds up tomorrow?
2. I have a spare, but un-tested engine in the yard, but it'll need a service and shims doing. I can do the service / shims, but then doing the
engine swap will take me a full weekend. Then if it doesn't work, or the gearbox is knackered, it'll take me another weekend to put the
current engine back in, complete with it's head gasket leak.
3. I have enough spare parts / engines to make a complete new engine...... but no experience in engine building and a gasket set is £150.
Cheers
Mike
its not likely to need a whole new engine, just sort the gasket that has blown.
I don't think You've got anything to lose by taking the cylinder head off to see if the head gasket has gone.
If it is the head gasket, it will be the quickest and cheapest fix.
If it isn't the head gasket then you don't have to decide whether to change the engine - that decision has just been made for you!
Cheers
Mark
Could it be the water pump allowing oil past, a bit unlikely but worth a look.
Steve.
I've bought some K-Seal and will chuck that in and then have a test drive.
I'm not sure about being able to do the headgasket on my own! Do you think I'd be able to do it with the engine in-situ?
Steve, I have a spare water pump, so could chuck that on if the K-Seal doesn't work.
Mike
there are some really helpful zzr forums out there. Bit quiet these days, but very knowledgeable group, especially the mod...muzzy I think his
username is.
anyhow, I would say with a haynes at your side, and everything stripped off the engine, it will be a pretty straightforward job. Just clean everything
before opening the engine. Then clean it again. 
online copy of the manual
http://www.scribd.com/doc/9582973/Kawasaki-ZX11-ZZR1100-9301-Service-Manual-ENG-by-Mosue
[Edited on 11/4/09 by Dangle_kt]
I've done the head gasket on my ZX9 engine twice. Not the same engine I know but it's really quite easy. It's not like a tin top job, a lot easier.
Trickiest bit is making sure you don't get shite into the water and oil ways.
quote:
Originally posted by mistergrumpy
I've done the head gasket on my ZX9 engine twice. Not the same engine I know but it's really quite easy. It's not like a tin top job, a lot easier.
Yeah I've done it with the enigne in situ. I've ha the block off it as well in situ. I got the gaskets from the local dealers. I've got
my receipt here 1 x head gasket £27.30 and I replaced the O ring on the camchain tensioner and the oil feed that comes up and into the top, they were
£1.50 all plus VAT. The timing chain is a delight to do nowt like a car. In fact it was that easy that I doubted I'd done it right both times and
redid it, so 4 times all in. 