Big-end Bearing Replacement

The zx6r (2000 model J1) tracky saga continues ... as I feared at the xmas trackday the big end on #1 has definitely let go. At this stage #2 & #3 seem OK and although I can't easily check #4 without splitting the case, given where the noise was coming from I suspect it's OK. So, the question in my mind is, should I drop the engine, split the cases, remove the crank and get it machined (if needed, but I suspect it will be) and replace the big-ends (all four obviously, I only want to do this once!), should I wreck it (it's probably worth more in parts, but having bought the 08 it would be nice to get the money in one hit instead of dribs and drabs), or bite the bullet and get it professionally rebuilt?

Who's done this themselves? Any gotchas? I'm pretty confident mechanically and built this particular bike from a wreck, but I've not had a bike engine's insides on the outside previously

If you've had similar work done before who did it for you and how much was it? Would you recommend them?

If I decide to part it out is anybody interested in anything in particular? Noteworthy parts include:
- straightened frame. Not recorded as a write-off, last registered with single seat rego in Qld
- Racetech fettled shock and forks. Gold valves, anti-dive valve in the shock, eibach springs
- Ohlins dampener (across the tank 916 style)
- Factory-pro Jetted carbs
- D&D system (re-skinned end pipe isn't real pretty)
- Wet4U race glass, painted green with a black bellypan
- Woodcraft 42mm clip-ons
- Tinted double bubble screen
- Front and rear wheels painted green (originally red)
- Braided lines

Finally, if anybody's interested in a 'project' tracky 'as is' then I'm open to offers.

Cheers,

Dave

Mate probably cheaper to get a replacement engine, the parts & labour will cost a small fortune on the old one.
Then sell the farker running with the old engine as spares you will make more $$$ that way
Then may I suggest getting a 10 so you can whip ass

i haven built any bike engines but i have builtplenty of others......just keep everything clean, measure everything twice and take notice of anything that looks out of the ordinary......anyone with a good mechanical knowedge and a manual would be able to do it

Then may I suggest getting a 10 so you can whip ass

+1

dave ,,if your going to fix it i'll give you a hand,,,a mate spun No 2 bigend on his 89 zx10 and was done on a weekend,,,should be about the same as that in a way,,,,cheers paul

Make sure you plasti gauge it to get the right shells mate. if it's a keeper, set it up a little looser as it will make more HP. But if you are intending flogging it, just make it quiet!!!

i just rebuilt my bottom end on my 253 for da ute dave, you can get away with not machining the crank, depends on how its been looked after, first off id check the cost of replacement main bearings and what sizes they have. would you bother doing the mains while your at it?
and i will lend a hand if its needed mate
cheers Tim

If you did decide to wreck it, I'd be interested in a few parts. The forks, steering damper, stator cover (if original design), brake lines. Really all depends on the price. Hell, if the price is good I might get the glass and stuff too and turn my own girl into a tracky (maybe if I get a pay rise, which I won't know till Feb).

Cheers guys. If I decide to rebuild it I'm going to do it properly, Jason, if I wreck it I'll let you know how much I want for those bits.

Any other experiences?

I have a top end sitting waiting for someone to buy it, was the one Dan got to rebuild his gearbox before he moved to Tassie. So gearbox cases are split, but crankshaft and top end are whole. Not sure how much Dan wants for it, but it's an option.

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engine2.jpg (67.1 KiB) Viewed 1428 times

engine3.jpg (71.37 KiB) Viewed 1428 times

dave if the $ are fair grab it ,,,will only need to buy gasket set,,,thats what i did on the zx10

I just got a message from Dan, he does not know the condition of this engine. He never turned it over, but simple used gearbox parts for his bike. The price is very good though...

dave if the $ are fair grab it ,,,will only need to buy gasket set,,,thats what i did on the zx10

I've actually still got a spare for parts so I wont need this one.

I just got a message from Dan, he does not know the condition of this engine. He never turned it over, but simple used gearbox parts for his bike. The price is very good though...

Thanks mate, but as above I have one and I reckon the postage to Sydney would kill me.

well pick a weekend and lets get into it ,,,,,,,make sure the bbq is clean,,,,,,i'll bring the grandsons project up as well,,,,,cheers paul

i'll bring the grandsons project up as well,,,,,cheers paul

WTF your a grandfather Paul You old bastard