ZX600c 1989 Stormtrooper Build - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 17 (permalink) Old 03-31-2016, 03:38 PM Thread Starter
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ZX600c 1989 Stormtrooper Build

So I picked up my first bike a few weeks back now. I posted about it in the noob section a while ago. I enjoy doing build threads cuz they keep me motivated so here goes

Picked it up on a tuesday night at 8pm and paid 360$ for it. Rode it home (first time on a bike bigger than a 80cc lol) and instantly fell in love. PO said the head gasket was good but after a few days of riding I decided to do a compression test and got a whopping 5psi in cylinder 4. Off came the head right away. After a bit of cleaning and inspection I decided to order a new used head from ebay. Found one for 75$ that supposedly had 19k on it. Head came in the mail last night and looks to be pretty damn straight with no stuck valves.

Somewhere in there I went nuts and probably spent around 800$ on parts. Ordered:
-Clymer manual
-head gasket
-exhaust gasket
-spark plugs
-new oil/filter
-pod style air filters
-carb rejet/rebuild kit
-LED headlights/steel for custom bezel
-all parts to repair my choke and hand controls (was a manual bicycle wire style choke lol)
-breathers for PCV and crankcase
-new battery
-heavy duty cooling system flush fluid for rust


Almost all of it has arrived so almost time for reassembly. Yesterday I re-jetted the carb for the first time (fingers crossed its good enough). Today ill be block sanding the new head... Going to take the head and as many parts I can into work to use the parts washer tomorrow.

Excited to get started on this thing! Think I'm going for a one-off streetfighter Stormtrooper look. Not going to start with any aesthetics until I get the bike clean and running great. Only time I ever got to ride it was was on three cylinders lol.

Now for a few pics so you know the piece of junk I'm working with

Night I brought it home:



Took the front end off to see if I could make any kind of headlight mount that would look good with stock gauges


Didn't like it at all so off came the gauges. Going to go with the Vapor gauge system eventually. Then grabbed these lights that will end up somewhere around here...


Some point the head came off. Pistons dont look terrible so I'm not going to mess with them


New head came so started cleaning


Pile of parts


Lastly the rear fairing ive been eyeing



Going to make a run to the stores and get materials for the head...
Hopefully will get that resurfaced and then i'll be off to my first MSF course tonight!
Jeff in Kentucky and GR rider like this.
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post #2 of 17 (permalink) Old 03-31-2016, 03:58 PM
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Garage
Im actually excited to see what this turns into!! Now if i could just find that damn subscribe button.
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post #3 of 17 (permalink) Old 03-31-2016, 06:50 PM Thread Starter
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Thanks man!

Also, if anyone has any info on converting from clip on bars to clamp style full bars let me know! I'll get to searching around eventually if not.
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post #4 of 17 (permalink) Old 04-01-2016, 03:38 AM
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Good luck and keep us posted, I am sure that you will end up with a cracking bike
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post #5 of 17 (permalink) Old 04-03-2016, 11:41 AM Thread Starter
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Haven't had much time to work on the bike... Did resurface the head and slapped that on. Also finished off the Carb! Deciding if I want to RTV the oil pan on or actually order the gasket. Don't really want to wait for the gasket...

I think I'll have more time this week to get it running!
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post #6 of 17 (permalink) Old 04-04-2016, 01:36 AM Thread Starter
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Well I threw the head on tonight and worked on getting the cams back in. Realized the junkyard that sent me new head sent me two #6 camshaft caps -_-
Hoping it'll be alright... Pretty mad though.

Thought I had it all together but must've got timing wrong. felt it not want to turn... I said **** it and turned out the lights. I'll give it another shot in a day or two
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post #7 of 17 (permalink) Old 04-05-2016, 03:24 AM Thread Starter
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Well made at least 6 attempt at getting the timing right... I'm turning the crankshaft by hand and once it gets one time around at TDC again it binds up and won't turn anymore. Not just compression resistance :/ reset the cams so many times I lost count.

So I spent the last hour dressing everything else up so its ready to run once timings correct. Just got to finish painting the exhaust tomorrow and then only thing left will be to fill up fluids and put valve cover back on.

Asked a buddy to come help with the cam setup later this week. Have pretty good amount of faith in him.

Really sick of this engine bullshit... Just want to get back to the fun stuff.
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post #8 of 17 (permalink) Old 04-05-2016, 11:56 AM Thread Starter
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Painted the exhaust this morning! Looks pretty nice. I'll throw that on when I get home.

Thinking of chopping the muffler in half, anyone know if this will affect the bike enough to where I can't use the jets I bought? I told them I had stock exhaust

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post #9 of 17 (permalink) Old 04-05-2016, 08:25 PM
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Cutting the mufflers in half will likely need carb rejetting, unless it was running rich (with extra fuel) before the muffler change.


Changing the air filter to more free flowing and changing the airbox are even more likely to need carb rejetting afterwards.
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“Banking institutions have banished precious metals and substituted a more fluctuating and unsafe medium; they have withdrawn capital from useful improvements and employments to nourish idleness for the few, who prefer demoralizing pursuits to labors useful to the whole; the peace of the whole is endangered by evils more easily to be deplored than remedied." by Thomas Jefferson,1810 (edited)
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post #10 of 17 (permalink) Old 04-06-2016, 01:23 AM Thread Starter
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Quote:
Originally Posted by Jeff in Kentucky View Post
Cutting the mufflers in half will likely need carb rejetting, unless it was running rich (with extra fuel) before the muffler change.


Changing the air filter to more free flowing and changing the airbox are even more likely to need carb rejetting afterwards.
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I already rejetted after air filters...
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