93-94 zxr750 cam timing marks ???

[willrcr15]

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We are restoring a zx7r from the ground up & started with a basket case as far as the engine goes Weve stripped it down & its like new inside, very happy, But weve struck a funny thing with the cams. When we set up as per the book, TDC on #1 & 4 & lign up the ex & in marks on the cams & set them 26 links apart the mark on the exhaust cam is slightly out( doesnt line up perfectly with the top of the head) very odd or is that normal?
Weve checked the chain for stretch but like the rest of the engine its perfect, has anyone struck this before?
I like to know its right before we reinstall it into the newly painted chassis so we arent doing it again. Ive ordered a Haynes service manual from UK but probably take a week or 2 & I'm trying to get her back on the road by Christmas

[JimZXR]

I'll have a look at my service manual tomorrow and let you know!

[JimZXR]

Extract from my manual:

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[willrcr15]

Thanks for going to that trouble,
Still unsure though, our dilemma is that when lined up similar to that in the above diagram we end up just off the crankshaft mark maybe what would be about half a link ??
Nothing seems to just line up perfectly, strange.
The service mechanics must hace come up against this when doing the valves, wondering which mark we disregard, its possible the crank mark is not right but seems right when we use a screw driver to feel TDC
Are there any Kwakka mechanics out there that know what to do ?
Regards
Mitchell

[Daisy]

Remember that the chain stretches over time - and they still run fine - so I don't think it needs to be absolutely precise in the beginning.

[willrcr15]

Hi all & Merry Christmas. We got her back together last night to the point where we tried the start button but, problem, when we pressed the start button the fuel pump made a noise & the headlights came on, & nothing from the starter motor. The wiring loom all seemed to go back together just right, the only loose ends we have are 2 black & yellow wires with open ends like they bolt on somewhere between the starter & battery region. We are very lost & it's a long shot but just hoping someone has had the same experience & has an answer.
Regards Mitchell.

[JimZXR]

Will lift the tank on the trackie tonight and have a look.
A picture would be useful though!

[Gosling1]

........ We got her back together last night to the point where we tried the start button but, problem, when we pressed the start button the fuel pump made a noise & the headlights came on, & nothing from the starter motor. The wiring loom all seemed to go back together just right, the only loose ends we have are 2 black & yellow wires with open ends like they bolt on somewhere between the starter & battery region. We are very lost & it's a long shot but just hoping someone has had the same experience & has an answer........

I'll take a punt here and guess that you haven't actually wired up the starter motor to the starter solenoid ? Although - normally a black wire with as yellow trace is an earth lead on most Kawasaki wiring looms..... You must have the earth lead from the battery connected, otherwise the headlights and fuel pump would not work.....what about the cut-out switches on the sidestand and clutch ? Are these working OK ?

The starter solenoid sits under the seat - there should be a thick lead running from one connection straight down to the starter motor. The other connection on the starter solenoid should be a thick red lead that runs directly to the battery +ve side.

If you can get a pic up, that may help.....

[willrcr15]

Thanks guys,
the starter & solenoid is all connected up properly, its even a new solenoid.
Yes the 2 wires are black with yellow lead, we'll look at them as earths.
We aren't familiar with these models, so what happens when you switch on the ignition? does the fuel pump pressurize or when the starter is pressed ?
The Haynes arrived finally, dad said it reads that the headlight comes on when the starter is pressed, we thought it was a haywire?
Maybe we just have a crook starter motor.
I'll try some pics again, I have tried in the past but they are always too big & don't know how to reduce them but I'll give it another go.
Regards

[JimZXR]

The lights come on once you let go of the starter button in mine.
The pump only starts when you press the starter motor on mine also.
Just thinking ahead; do the wires you mention have push in connectors? If so, are they the wires for the side stand switch? Nothing will happen if they're not connected!

[willrcr15]

The side stand switch is all connected up & stand is up. also clutch switch is engaged.
That's good news re the light & pump, seems we might be closer than we thought last night, maybe it's just the starter motor.
I'll get a pic of the wires, still trying to reduce a one, think I might have it worked out.
How many wires are on the starter & battery, mine is just single wire connections?

[JimZXR]

Have just looked at the loom on my trackie and Gos has it spot on!
One side of the wire is connected to the battery negative, the other to the frame via a shared bolt on the fuel pump bracket.
Shot of the battery end below but can't get a clear one of the pump side.

[JimZXR]

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[JimZXR]

The open ended (fork) fitting goes onto the battery negative, the other goes on like I deacribed above!
Hopefully that sorts it but not sure why that'd affect the starter motor as the motor is also connected to the battery negative!

[willrcr15]

Thanks for the help, sounds like its all wired correctly, must be a crook starter motor, we'll find out soon.
I'll post some recent pics if anyone's interested, just waiting for the paint shop to re open so I can finish the fairings & tank.
regards, Mitchell