Project: 1990 ZR550 Zephyr (yes, another one)

Since my cam cover situation is on hold (different thread), I decided to try and button it up with what I have. I checked to make sure it would turn over, checked the cam chain timing, and valve clearances. Everything checked out so I installed the stock cover and called it good. I suppose it’s entirely possible that there’s something somewhere in the engine that the PO didn’t torque to spec or remember to oil/grease, but as it sits right now I’m gonna take that risk, fill it, and fire it. 

Remember to remove the cam chain tensioner cap and spring BEFORE tightening down the cam cover. The chain runner in the cover presses down on the chain, between the two cam sprockets. 

H.
 

Ah crap, you’re right, I totally forgot. I can still remove the tensioner, reset it, and reinstall it right? 

Yes, remove the cap and spring, then slowly rotate the crank backwards about half a rev and reinstall the spring and cap, to allow the tensioner to extend into the "slack" and you should be good. (Be aware that the starter will be driven by the the reverse rotation)

H.

Resetting the cam chain tensioner to find that I have a stripped cap bolt. Or rather, the threads the cap bolt thread into are stripped. Luckily I should still have the tensioner I replaced on my other bike. See? I knew there was a good reason to have two of the exact same bike. 

Starting the paint process on the body work this week. 

 

Nice job on the painting parts rack.
I use two 12' lengths of perforated angle iron for hanging garage door openers. One for all of the parts and one to hang the frame from.

Kelly that is some impressive shop space you have there 

Thanks Wookie, it's 1400sqft with 12' 6" ceiling height and heated. It's big enough to share work space with two of my friends.

Consider me jealous. I make do with the little bit of space I have, but it would be nice to spread out a bit more. 

Painting went well I’d say. 
 

The fender is painted brown as well, but I need to rivet it back together with the brace still. I also have some ideas for a tank badge/decal. 

Tomorrow I’m gonna pick up some oil, a battery, and some gas, and see if she starts. 

Wow, you've made a lot of progress in a very short time! Good luck on the first start up I know how nerve racking that can be with an unknown bike.

One question....is the front tire installed in the right direction? I always thought the tread should wick the water away from the center of the tire.