Annoying little things

dklay · 09-08-04, 05:06 PM

Since I've been doing a bit of carb work and maintenence lately, here's some things that I've found about the ZR-7 that are annoying. They suggest to me that the bike was designed by engineers with very little consult to mechanics, who actually have to take the things apart.

1. The rear gas tank bracket that bolts to the frame. Couldn't they have designed it so that you don't have to remove it to be able to get inside the airbox???

2. You have to remove the cover(s) from the airbox (as well as the previously mentioned bracket) in order to get at the battery.

3. Why couldn't the throttle cables attach at the top of the carburetors, so they could be easily disconnected? It's truly a pain in the butt to get them disconnected and connected again- I've had to disconnect the cables at the throttle grip to get enough slack to re-connect them

4. If there were about 1/2" more play between the airbox mixing chamber and the frame rail, you'd be able to just slide the airbox backwards to get the carbs out.

5. Phillips screws. They strip WAY too easy. Would it be so hard to use hex heads or allen heads everywhere?

6. The spacers that go between the wheel and the swingarm/ fork tubes. Seems every time I try to re-mount a wheel, I fight with these things - knocking one out of place while trying to slide the wheel up and simultaneously slipping the axle back in.

I'm sure there are other things, but those are the first to come to mind right now. Other than that, the bike's great!!

graeme gould · 09-08-04, 07:02 PM

Sounds like you have been tinkering with the carbs and the back wheel.

I always seem to have trouble with the front wheel alignment of the speedo drive and fork guide.

gg@lamchabang, ava good day

madbam · 09-08-04, 07:13 PM

Yeah...I fully agree with #'s 1 and 2 since I had to get a new battery recently....what a pain in the A$%

javasutra · 09-08-04, 08:53 PM

I've been through all six and I agree. The airbox situation is probably my least favorite.

GG, I've been wondering about that speedo drive lately. When I put it on seemingly according to the manual, the speedo cable seems to be very kinked near the hub. It was this way from the shop so I've always assumed that it was the right way. It seems, though, that the coupling for the cable should be closer to the ground so the cable is less stressed.

Bronto · 09-08-04, 09:20 PM

Agree with #1. Only salvation was discovered a phillips screw driver will fit the allen hex bolt. Enough to loosen or tighten a little, when its loose.
Someone was saying changing the spark plugs on a Ducati, nearly had to remove the engine. So it could be allot worse

graeme gould · 09-09-04, 07:14 PM

If you feel it is "kinked" more than likely it is, have a look at another zr7 or some friendly forumer may post a pic of the speedo cable to axle connection. As I remember the cable enters the drive at about 20 degrees below the horizontal

gg@lamchabang Thailand

javasutra · 09-10-04, 09:06 AM

I definitely have it wrong, then. My cable is entering the drive about 20 degrees above horizontal. I'll loosen the axle and see if I can get it rerouted.

javasutra · 09-10-04, 11:48 AM

I have another one to add to the list. This one is probably Keihin's fault but..

7. The drain screws on the carbs all point to the right. This makes it a real challenge to get to #1 and #2 to drain the bowls.

Regarding number 4, I pulled the boots out of the airbox before removing the carbs the last time. They're something of a pain to get back in but the carb bank comes out and goes in much, much easier with the boots off.

graeme gould · 09-10-04, 09:05 PM

Those carb drains screws are trickey, I removed the carb heaters permantely to give me better access.

gg@lamchabang T'land, ava good day

09-08-04, 07:13 PM	#3
madbam Up-And Comer Join Date: Aug 2004 Location: Poughkeepsie, NY Posts: 83	Yeah dk Yeah...I fully agree with #'s 1 and 2 since I had to get a new battery recently....what a pain in the A$% __________________ J--E--T--S...Jets..Jets.Jets

09-08-04, 09:20 PM	#5
Bronto Supreme Being Join Date: Mar 2003 Location: Alamo, CA Posts: 1,608	Agree with #1. Only salvation was discovered a phillips screw driver will fit the allen hex bolt. Enough to loosen or tighten a little, when its loose. Someone was saying changing the spark plugs on a Ducati, nearly had to remove the engine. So it could be allot worse __________________ Semi Truck air flow Video. ______________________________Alan____ Red Zx6r & Green GSX1300R - Former Blurple Zr7sS rider

09-09-04, 07:14 PM	#6
graeme gould Maintenance Overlord Join Date: Oct 2001 Location: Byron Bay Australia Posts: 5,554	Hi Java If you feel it is "kinked" more than likely it is, have a look at another zr7 or some friendly forumer may post a pic of the speedo cable to axle connection. As I remember the cable enters the drive at about 20 degrees below the horizontal gg@lamchabang Thailand __________________ Graeme Gould at Byron Bay the most Easterly part of Australia

09-10-04, 09:05 PM	#9
graeme gould Maintenance Overlord Join Date: Oct 2001 Location: Byron Bay Australia Posts: 5,554	Yes Java Those carb drains screws are trickey, I removed the carb heaters permantely to give me better access. gg@lamchabang T'land, ava good day __________________ Graeme Gould at Byron Bay the most Easterly part of Australia

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09-08-04, 05:06 PM	#1
dklay Timex Join Date: Nov 2002 Posts: 763	Annoying little things Since I've been doing a bit of carb work and maintenence lately, here's some things that I've found about the ZR-7 that are annoying. They suggest to me that the bike was designed by engineers with very little consult to mechanics, who actually have to take the things apart. 1. The rear gas tank bracket that bolts to the frame. Couldn't they have designed it so that you don't have to remove it to be able to get inside the airbox??? 2. You have to remove the cover(s) from the airbox (as well as the previously mentioned bracket) in order to get at the battery. 3. Why couldn't the throttle cables attach at the top of the carburetors, so they could be easily disconnected? It's truly a pain in the butt to get them disconnected and connected again- I've had to disconnect the cables at the throttle grip to get enough slack to re-connect them 4. If there were about 1/2" more play between the airbox mixing chamber and the frame rail, you'd be able to just slide the airbox backwards to get the carbs out. 5. Phillips screws. They strip WAY too easy. Would it be so hard to use hex heads or allen heads everywhere? 6. The spacers that go between the wheel and the swingarm/ fork tubes. Seems every time I try to re-mount a wheel, I fight with these things - knocking one out of place while trying to slide the wheel up and simultaneously slipping the axle back in. I'm sure there are other things, but those are the first to come to mind right now. Other than that, the bike's great!!

09-08-04, 07:02 PM	#2
graeme gould Maintenance Overlord Join Date: Oct 2001 Location: Byron Bay Australia Posts: 5,554	Hi dklay Sounds like you have been tinkering with the carbs and the back wheel. I always seem to have trouble with the front wheel alignment of the speedo drive and fork guide. gg@lamchabang, ava good day __________________ Graeme Gould at Byron Bay the most Easterly part of Australia

09-08-04, 08:53 PM	#4
javasutra Silver Member Join Date: Feb 2003 Location: Nicholasville KY, USA Posts: 1,941	I've been through all six and I agree. The airbox situation is probably my least favorite. GG, I've been wondering about that speedo drive lately. When I put it on seemingly according to the manual, the speedo cable seems to be very kinked near the hub. It was this way from the shop so I've always assumed that it was the right way. It seems, though, that the coupling for the cable should be closer to the ground so the cable is less stressed.

09-10-04, 09:06 AM	#7
javasutra Silver Member Join Date: Feb 2003 Location: Nicholasville KY, USA Posts: 1,941	I definitely have it wrong, then. My cable is entering the drive about 20 degrees above horizontal. I'll loosen the axle and see if I can get it rerouted.

09-10-04, 11:48 AM	#8
javasutra Silver Member Join Date: Feb 2003 Location: Nicholasville KY, USA Posts: 1,941	I have another one to add to the list. This one is probably Keihin's fault but.. 7. The drain screws on the carbs all point to the right. This makes it a real challenge to get to #1 and #2 to drain the bowls. Regarding number 4, I pulled the boots out of the airbox before removing the carbs the last time. They're something of a pain to get back in but the carb bank comes out and goes in much, much easier with the boots off.