ZL600 A1 rings help

[ZL JIM]

Still getting the hang of this site. Anyways , i just picked up an 86 ZL600 with bad rings. Nobody seems to have them. Any help would be appreciated. Bore is still in spec, just glazed. I thought about ball honing and sticking it back together. Only has 22k , my experience tells me Japanese bikes run forever. Previous owner put straight pipes on. UGH.

 

[furchin]

This Kawasaki 13008-1074 RING-SET-PISTON,STD fits the following models and components:

Kawasaki Motorcycle 1987 ZL600 Eliminator - ZL600-A2 Cylinder, Piston

Kawasaki Motorcycle 1986 ZL600 Eliminator - ZL600-A1 Cylinder, Piston

Kawasaki Motorcycle 1986 Ninja 600 - ZX600-A2 CYLINDER/PISTON (-E/NO.037152)

Kawasaki Motorcycle 1985 Ninja 600 - ZX600-A1 CYLINDER/PISTON (-E/NO.037152)

Kawasaki Motorcycle 1997 Eliminator 600 - ZL600-B3 Cylinder/Piston(s)

Kawasaki Motorcycle 1996 Eliminator 600 - ZL600-B2 Cylinder/Piston(s)

Kawasaki Motorcycle 1987 Ninja 600RX - ZX600-B1 Cylinder/Pistons

Kawasaki Motorcycle 1987 Ninja 600 - ZX600-A3 Cylinder/Pistons

Kawasaki Motorcycle 1985 Ninja 600 - ZX600-A1 CYLINDER/PISTONS (E/NO.037153-)

Kawasaki Motorcycle 1986 Ninja 600 - ZX600-A2 CYLINDER/PISTONS (E/NO.037153-)

 

[R. J.]

You need to get a set of cyn ball roller calibers/micrometers and check all 4 cyns bores. You may want to call WISECO. They don't list piston sets for the ZL 600 but that doesn't mean that they don't carry them. They also have a sister company J. E. Pistions that might carry kits for the ZL 6. WISECO. http://www.wiseco.com/ProductSearch.aspx . J. E. Pistons. https://www.jepistons.com/ .

 

[ZL JIM]

Thank you RJ, will do.

 

[ZL JIM]

FYI, i did measure the cylinders, all are in spec 59.9mm . Bores are glazed, no cross hatching except at the bottom of the cylinders. Starting to wonder if the bike was sitting and had the ring dunked and thats why it had low compression . Stuck rings ?? 22k is nothing on a Kawi motor. Am I delusional??

 

[87kawzl]

Did you adjust the valves before the compression test? An oz of oil in the plug hole then testing again will point you to which end your losing compression. If it tests good when you do that it's the rings, if no boost on the gauge it is the valves.

The cross hatch on the bore usually fades away with some miles.

 

[ZL JIM]

I did follow, checking valve clearance first. Then compression check, 1,3 lower than 2 and 4. added oil and 20-30 psi change. Pulled the head and saw a lot of carbon on cylinders 1,3. I believe this bike was running very rich on those cylinders. for awhile. I used alcohol and checked each intake and exhaust port after head was removed, found 1 exhaust valve on #3 cylinder drip. Also confirmed the buildup of excess carbon in cylinders 1,3 exhaust ports.

 

[87kawzl]

Looks like Furchin gave you some good places to start. A shop shouldn't charge much to dress the cylinders out when you find some rings. Good luck

 

[ZL JIM]

Thank you!! Ill keep looking. FYI the top of my coils are labeled 1,3 and 2,4 from the left coil to the right coil? the manual says left coil is 1,4 and right coil is 2,3 ? any thoughts??

 

[R. J.]

Found this for checking cyn bore. https://www.amazon.com/Professional...77&sprefix=motorcycle+cylinder,aps,178&sr=8-1 . They have different models with different ranges. Does anyone know what range is needed for motorcycle cyns.

 

[ZL JIM]

ordered one from them , 60mm is 2 3/8 or so and you would order a 2 1/2 ball hone. Always order 1/4 ' or so bigger than cylinder size.

 

[ZL JIM]

Alright, Honed the cylinders , replaced head gasket. Cleaned valves and checked the for leaks with alcohol in the ports. Checked timing chain and reassembled. Installed 117.5 mains and 2 #2 washers under needle valve. Upped pilot to 45 and installed pods, using original intake boots. Set pilot screw to 2 1/2 turns and let it fly. It runs like a beast. Not sure what the compression is back to at this point , but i'll break it in as " new " rings and check after 500 miles.

 

[furchin]

Yahoooo

 

[Trojan441]

Thank you!! Ill keep looking. FYI the top of my coils are labeled 1,3 and 2,4 from the left coil to the right coil? the manual says left coil is 1,4 and right coil is 2,3 ? any thoughts??

Pretty sure, that the firing order has to have the coils in the 1 & 4 then 2 & 3 coil terminal position, on all small fours, that is 400 & 600 cc bikes. Also make sure the wiring to the coils is in the right order, it is hard to mix up usually, because of the length of the wires.

 

[ZL JIM]

Trojan441 ,
thank you, that is how i wired it. It runs so, all good!!