GPZ11 Injection

[moizeau]

Photos at it's new home.

pipes

The bad bit, when it popped apparently it pushed the cam cover up!

Some nice extras that I didn't know about

So first job is to pull the spare engine apart and see what's usable, then the engine in the bike. I can then work out what needs sourcing and how many beer tokens it's going to cost. The spare head 'looks' OK apart from a coup,le of sheared exhaust studs but we will see.
Looks like the next immediate investment is a valve spring compressor and a workshop manual. The chap did give me a 'Revue Technique' that oddly also covers the VF750. Not perfect but it's a start.
To my very untrained eye I seem to be missing the centre stand, front indicators and mirrors.
The fun begins.....

[r3sc]

Really looking forward to the next instalment!

[Philippe]

Hi Pete
very nice surprises! You're a lucky B...d.
If you need any advice, don't hesitate, ask!
GrtZ
Philippe

[moizeau]

Philippe, I am, just checked, my mother and father were married when I was born, so all good so far.Just checked the engine numbers of the spare engine, it's an A1, so good. If anyone has a workshop manual....Mark..., and the parts manuals went to microfiche, so apparently they longer exist?

[Ultim8pc]

Excellent stuff.

[Swirl]

Looks good

[moizeau]

Any recommendations on valve spring compressors, I don't need a pro grade one as I won't be doing this every week, but I've seen two designs, one with a screw and one with a clamp ( like big mole grips) mechanism. The last time I did this was about 25 years ago with a Dolly Sprint engine.....that was a clamp one. Price varies massively.
All suggestions gratefully received.
Cheers

[moizeau]

Minor update, had a look at the spare barrels, they are 1170, 75mm. Anyone know the maker of the pistons? There's a 'C' stamped in the crown. Crap photo, sorry.

The Head, both studs from No.1 were sheared, I got 5 of the other 6 out with locknuts and a plumbers torch. The last one, top most of of no.2, after loads of heat sheared leaving the flank of the stud.
'Nuther problem, after looking through the bits, I've not got the cam caps for the spare. I'll try the others and check with plastiguage. Not touched the engine in the bike yet...
More fun to come..........

[Al]

Could be Cosworth pistons!
AL

[Robw]

If they are Wiseco, there should be W on the casting inside of the piston on the small end.
Rob

[moizeau]

No marks on the inside at all, just a 'C' and the arrow on the crown. There seems to be a reinforcement on the inner crown that's peened into the holes for the oil scraper ring. Slightly better photo but not great.

[moizeau]

Any advice on a Valve spring compressor chaps? Links welcome (please help a learning muppet).
Cheers

[moizeau]

Small update, but many hours. The spare head had it's sheared exhaust studs sorted. The two the were already sheared were drilled and tapped, No.2 cylinder, top stud didn't want to go, sheared leaving me 20mm, then the welder packed up, went up my mate's, welded a nut on, loads of heat, sheared again. So it got cut off, drilled and tapped, using my Heath Robinson jig to make sure the angles were correct.

Checked the threads in the head, one was sheared, and has been for a long time judging by the fact that it's been machined or finished true. Going to stick the cam cover on to get a centre mark, then drill and tap that out.
One cam cap thread is a little loose. Oh and I've no cam caps for this head....Will play, change around and plastigauge the one's I have from the original motor to see if they will do.
Still not touched the actual bike yet....

[moizeau]

Just about to split the casings on the spare engine.
The rotor is knackered, one of the magnets has been obliterated. I'm guessing this is 'special tool' only for removing it? I've undone the nut with a bar though the hole in the rotor ('cause there's no magnet there) but will have to take the (hopefully) good rotor off the engine in the frame, so a rotor holder is needed as well but I plan to make this. I'm planning on using the crank from the spare in the existing lump. Not sure if the existing one will be healthy after busting it's chain at speed, not sure about the casing of the existing either though at the moment.

[moizeau]

Update, the top end is off.
Whilst pulling various bits off to allow me to get the engine out easier I noticed that the inlet rubber for no.2 was loose, the LH middle exhaust side cylinder head nut was loose, partially stripped. The air box was very oily on the left hand side. The air filter fell apart when removed. The pre filter looks very gunged up. The LHS 6mm cylinder head bolt was stripped.
Very surprised to find an intact cam chain in the engine, albeit fallen down into the engine. I've got the broken one in a box of bits so someone has replaced it. Will be emailing the previous owner to find out a bit more history. The green base gasket as well as the green pickup cover gasket look quite recent.
This is the head once removed, no.2 exhaust shim is in bits!.

The front and rear cam chain guides are very worn. It looks like tensioner has been overdone looking at the rear

The barrels show quite a few vertical scores that can be just felt with a finger nail, more so at the base of the cylinders.
The pistons fitted are 74mm. Giving the damage to no.2 exhaust shim, there is no marking on the piston!
Oh, and the bottom end is seized solid but all big ends feel OK. It's guess work until I pull the engine out but will be interesting to see if it's the remains of the broken chain or a crank shell.
Seeing the condition of the 2 top ends, the spare head is the way to go (cam caps unknown so we'll see). The spare barrel liners and pistons look good but it has damage to the fins, not massive but the bike barrels externally look great but have scoring. Thinking of changing the liners and pistons. Is this even feasible? Please advise oh knowledgeable ones.
I'm thinking that after the first bust chain it was 'repaired' on the cheap.
The bottom end.....who knows at the moment....