Finally killed the ZZR engine.......
jossey - 6/4/11 at 08:17 PM
Well im sure alot of you know about my zzr engine issues.
well today i finally sorted them....
I sorted the air leak and it ran sooo well.
after leaving it to warm up i gave it a bit of throttle to about 11,000 rpm and the next thing i know a con rod flew out from under the engine.
needless to say the engine is dead.
The guy who rebuilt it i guess didnt lock tight the nuts and bolts and see below for the result.
Anyway its a shame cos the engine had only done 20,000 miles since new....
Your views will be helpful as always. least i have decided between bike and car engine.
ill get the new carbs exhaust and wiring n sling on ebay. if you need owt let me know.
sideview2
on floor undamaged....
[Edited on 6/4/11 by jossey]
HowardB - 6/4/11 at 08:20 PM
ouch!
big_l - 6/4/11 at 08:22 PM
oh cock oh well there is plenty more out there 
at least you now have a spare gear box starter clutch etc etc think of all the positives
femster87 - 6/4/11 at 08:23 PM
ooh, what have you done
jossey - 6/4/11 at 08:37 PM
Good way to look at it. lots of spares now lol
femster..... i foooked it lol
ran sooo sweet till it blew a hole in side of engine lol
coyoteboy - 6/4/11 at 08:56 PM
Plenty more out there?! Where? People keep saying this but I can never find one at a sane price.
I do actually know of a chap who was trying to ebay one in bits, in case you want to get the cases and bits you need from him.
Was it #3 rod and the well known #3 under-oiling?
[Edited on 6/4/11 by coyoteboy]
Lightning - 6/4/11 at 09:04 PM
you must be gutted. these things are sent to try us. best of luck with whatever you decide to do
matt_gsxr - 6/4/11 at 09:44 PM
sorry to hear of this outcome.
Focusing on the positives, you are learning a lot about bike engines.
And, well done on fixing the air leak.
And, it was always going to go, so better now than on the motorway on the way to your IVA test.
Are you going to try to get another the same, or going CEC?
Coyoteboys mates bits are on e-bay:
Kawasaki ZZR1100 Complete Engine Parts on eBay (end time 12-Apr-11 19:37:19 BST)
Mr Whippy - 6/4/11 at 10:32 PM
what a pest hope you get something sorted soon, at least your not hurt
jollygreengiant - 6/4/11 at 10:34 PM
quote:
Originally posted by jossey
Good way to look at it. lots of spares now lol
femster..... i foooked it lol
ran sooo sweet till it blew a hole in side of engine lol
I know the feeling. 17 years old and I managed to to the same to my dads recently rebuilt 1600Xflow mk 2 cortina estate (Fully loaded back end, it
took two cars to unload what was in the boot), whilst keeping up with a Fiat Mirafiori 131 Twin cam down the M27 whilst heading towards Romsey. Dad
was asleep in the back and mum asleep in the front, until THE bang, that is. I'm still not sure which made the most noise, the bang or my mums
whingeing, dad was fairly philisophical about it. Until the bill came in for a NEW engine, the only useable bits were the manfolds and rocker cover
(dented from the inside). Sorry no pics, it was 32 years ago.
165/13 tyres, 4.25 diff pulling about 90mph for about 15 miles and the fiat was not getting away.
jossey - 7/4/11 at 07:48 AM
Coyote .... No it was number two what came out.
The chap you know with one in bits maybe handy cheers
Matt....
Cheers for eBay link I've messaged him.
Ye I was pleased I'm getting my head around how it works. Is a shame but I guess it could have been slot worse. Funny thing was it was still
Running after the big bang lol I had to run to the stop button.
About the deciding on what to do next BEC and CEC
Well if I can get a cheap Zzr1100 then I'll stay BEC but if not then there is a ton of v8's for a few hundred quid.
The bike sounded so sweet when I fixed it all 
Cheers All
[Edited on 7/4/11 by jossey]
[Edited on 7/4/11 by jossey]
matt_gsxr - 7/4/11 at 09:30 AM
Jossey,
I cracked a barrel the other day after I put the turbo on. Too much compression and too little caution!
Its annoying, but I picked up a set of pistons and barrels for Ģ50.
So, the good thing about these old engines (mine is 1994) is that the bits are pretty cheap. The cost of gaskets and oil becomes more than the bits
themselves.
If you do change direction then think really carefully. You could end up with lots to change (i.e. diff, springs, engine mounts, exhaust, propshaft,
potentially chassis rails, fueling). I am not trying to put you off, but the route to a timely and cost effective build is to have a good plan and to
stick to it.
Matt
jossey - 7/4/11 at 10:31 AM
hi matt,
ye it makes sense ive built the chassis with welded mounts for the engine and everything is setup that way.
ill keep my eye out for another zzr1100 engine and with any luck ill get something.
that engine cost me nothing which makes me feel a little better. as i bought the whole bike n sold off the bits.
sorry to hear about your mishap.
ill keep on trucking with the bike engine idea. i have enough other stuff to be going on with lol
dave
Major Stare - 7/4/11 at 08:23 PM
Bad news on the engine but i agree with Matt. You have everything there to put a new/replacement engine in with minimal effort. Swapping to CEC will
potentially cost more and take a considerable amount of time.
My two pence - fit another ZZR engine and keep whats still works as spares or sell on to fund the replacment engine.
mark.s - 8/4/11 at 10:02 AM
what is the engine model c or d ?
jossey - 8/4/11 at 08:43 PM
It's a c model but most of c bits fit I've been told.
Angel Acevedo - 12/4/11 at 01:22 PM
quote:
Originally posted by jossey
Well im sure alot of you know about my zzr engine issues.
well today i finally sorted them....
I sorted the air leak and it ran sooo well.
after leaving it to warm up i gave it a bit of throttle to about 11,000 rpm and the next thing i know a con rod flew out from under the engine.
needless to say the engine is dead.
The guy who rebuilt it i guess didnt lock tight the nuts and bolts and see below for the result.
Anyway its a shame cos the engine had only done 20,000 miles since new....
Your views will be helpful as always. least i have decided between bike and car engine.
ill get the new carbs exhaust and wiring n sling on ebay. if you need owt let me know.
sideview2
on floor undamaged....
[Edited on 6/4/11 by jossey]
Jossey,
Donīt want to be rude, but revving an engine that high with no load was not very wise. Or is it a common practice?
I donīt know what the redline is, but I wouldnīt want to go beyond halfway or three quarters of the rev range with the engine with no load.
Also, you state that the engine builder didnīt "lock tight" the nuts and bolts, what do you mean by this? That he didnīt use full torque? or
that he didnīt put threadlocker?
Anyway, a connecting rod coming loose must have made a lot of noise before going away like this one did.
Hope this helps somebody in the future avoid this result.
Regards
AA
Guinness - 12/4/11 at 01:56 PM
As far as I know the bolts on the con rods are a one use only deal.
Is this what happens if the engine has been apart and the bolts re-used rather than replaced???
Anyway, can everyone please stop killing big ole zeds. Where am I going to get my next one from! 
jossey - 15/4/11 at 04:15 PM
i bought it from a guy who had just had it rebuilt so i guess it was done wrong looking at the damage lol
ive bought a d model now.
just need to know what will go from my c3 to the d model engine....
quote:
Originally posted by Guinness
As far as I know the bolts on the con rods are a one use only deal.
Is this what happens if the engine has been apart and the bolts re-used rather than replaced???
Anyway, can everyone please stop killing big ole zeds. Where am I going to get my next one from!
jossey - 15/4/11 at 04:21 PM
i dont really know very much about the engines. but when ive been watching people testing engines when they have been buying them or putting them in
their bike ive seen them red line it before installing.
noise wise there was no noise till the big bang.
threadlock is what i meant which seems to be the reason it came lose.
im unsure about if you should or should not rev a engine that high but you learn something new everyday.
the load shouldnt make any difference. i see enough biker mates red lining the bikes on the spot with it in neutral.
.....
quote:
Originally posted by Angel Acevedo
quote:
Originally posted by jossey
Well im sure alot of you know about my zzr engine issues.
well today i finally sorted them....
I sorted the air leak and it ran sooo well.
after leaving it to warm up i gave it a bit of throttle to about 11,000 rpm and the next thing i know a con rod flew out from under the engine.
needless to say the engine is dead.
The guy who rebuilt it i guess didnt lock tight the nuts and bolts and see below for the result.
Anyway its a shame cos the engine had only done 20,000 miles since new....
Your views will be helpful as always. least i have decided between bike and car engine.
ill get the new carbs exhaust and wiring n sling on ebay. if you need owt let me know.
sideview2
on floor undamaged....
[Edited on 6/4/11 by jossey]
Jossey,
Donīt want to be rude, but revving an engine that high with no load was not very wise. Or is it a common practice?
I donīt know what the redline is, but I wouldnīt want to go beyond halfway or three quarters of the rev range with the engine with no load.
Also, you state that the engine builder didnīt "lock tight" the nuts and bolts, what do you mean by this? That he didnīt use full torque? or
that he didnīt put threadlocker?
Anyway, a connecting rod coming loose must have made a lot of noise before going away like this one did.
Hope this helps somebody in the future avoid this result.
Regards
AA
mattyc - 15/4/11 at 06:12 PM
Cheap zx10 engine going in the for sale section would fit nicely were yours is!!
