Inspecting Pistons and Honing Cylinders on my ZX7R - Ep7 | ZX7R Restoration | Tom's Workshop

With next to no history on this engine, I want to check the condition of the hardest working of the engine parts, the pistons, rings & cylinders. I'll also have a go at honing the cylinder walls too.
Tools:
Cylinder Hone: amzn.to/3TrpXuD
50-75mm Micrometer: amzn.to/3tk34yN
Telescoping Gauges: amzn.to/3RqMEMV
Ultrasonic Cleaning Tank: amzn.to/3GLx3me
Subscribe to follow the progress!

[@ChrisSofos]

Very well done mate!!! I loved the addition of the 3-D graphics!!!

[@tomsworkshopprojects]

Haha cheers Chris, enjoying playing around with new ways of showing things. Good excuse to learn a new skill 😂

[@jasonbrown1237]

Love the build so far Tom, just wanted to give a little advice. You never want to stop the hone in the cylinder when you are putting the crosshatch.

[@tomsworkshopprojects]

Good tip, cheers! In all the research I did there were such conflicting thoughts on it. All experienced points of view as well, but I do see the logic of not stopping.

[@alanrobins]

Another excellent video keep up the good work The little knurled cap on the end of the micrometer is for accurate tension on your measurement Very proud again Dad

[@jackmiller8851]

Tom, it's ridiculous how much effort you're putting into these videos. I think i've been subscribed for close to a year now, and you're still at it. I know it's a niche subject so I just wanted to say thank you and also to encourage you (not that you need it!) to keep going. It's such a pleasure to see.

[@tomsworkshopprojects]

Cheers mate 👍🏻 still very much enjoying making them and hearing from people who get a kick out of watching!

[@SuperbikeSurgeryTV]

Well done mate, you are making good progress 👍 A couple of top tips for you if I may! Always replace the rings if at all possible. They lose their energy (Springiness) over time. Even if they measure ok in terms of dimensions it doesn't mean they are ok. Cylinder wall finish is also really important. The Grit and material the hone is made from can really affect the surface finish, which in turn affects the longevity of the engine. After honing you need to spend a lot of time cleaning the cylinders. Just because they look clean doesn't mean they are clean enough!

[@tomsworkshopprojects]

Thanks Jim! Really appreciate you watching and the tips. I've learned a huge amount from your vids over the years and often go back to the GSXR750 engine series for the valuable insights you share about these things. My first time inside an engine is a wee bit less daunting as a result! I think I'm going to replace the rings prior to reassembly just in case, along with a good clean of the cylinders. I'm now convinced it's a worthwhile cost.

[@SuperbikeSurgeryTV]

​@@tomsworkshopprojects You are very welcome mate, keep up the great work!

[@richb5248]

Hi Tom, I’m sure you know but it didn’t show in the video. You should always use the little ratchet on the end of the micrometer so that you apply the same pressure when measuring. Otherwise you are relying on your own internal calibration of using the same finger/thumb pressure each time you measure something. Great episode again, really looking forward to the next one. . . .However long it takes.

[@tomsworkshopprojects]

That makes a lot of sense, I hadn’t quite found a solid answer as to what the ratchet was for, I’ll bear that in mind for future measurements!

[@stevehignett5701]

Hi there, I'm late to watching the video, so I'm sure you might have been told already by now, but to get accurate and respectable readings, you have to use smaller, outer ratcheting dial wheel when taking measurements. It has a ratchet set to a specific slip to ensure that it gets to a certain level of tightness and no more. The way you used the micrometer isn't reliable nor accurate. Hope this helps?

[@dennisobrien2578]

If you are reusing the original, or not new cylinder head bolts you have to use the used torque spec. Once they have been stretched you don’t want to stretch them again. The torque spec is in the manual

[@tomsworkshopprojects]

Thanks for the tip 🙏🏼

[@derf9465]

I have a bent oil ring from my ZZ7R P6.....As I slide the cylinder block down the wee ring popped out and it slid down with ease, nothing hanging up until it stopped. 1 new liner later. Very happy bike. Just reminds me, one little miss hap can cost and slow down a project. Kamakazi took 6 weeks to ship from Japan.

[@tomsworkshopprojects]

Ouch 😩 yeah I’m a little apprehensive about reassembly, If I end up splitting the cases I’ll probably fit them in one by one and do the gudgeon pins from underneath.

[@patrickhostler5939]

I have never known how honing is actually done… but now I do!!! Superb attention to detail as always. ❤

[@missydee6085]

Cheers for sharing the fascinating work on the ZX7R, Tom. It's also resulted in some excellent advice by a few viewers regarding the honing process too eg Don't stop the honing tool in the bore; & clean the cylinder after each sweep & then re-lubricate before every additional pass. Every day's a school day! I hope you & yours have a smashin' Crimbo+ - and here's to the next exciting installment 😉

[@tomsworkshopprojects]

Thank you! And to you 🎄 I agree, it’s becoming my favourite part of this process, people sharing advice and tips. I’m no pro, so I’m always looking to learn from the experienced among us!

[@cm4734]

Really enjoying all of your hard work. Keep up the good work.

[@karlvanboxel561]

Good job on the honing. Tom especially seen as how you’re new at this I’ve seen plenty if people get this utterly wrong and it’s important step nice work

[@t20f70]

Hi Tom, I'm following these videos of yours dedicated to the zx7r and I must offer you my most sincere compliments first of all for your expertise and then for the clarity in the images of the various phases and also for your truly high-level workshop equipment. I live in Sicily and I have a ZX9R (2002 model) and you don't know how much I would love to have a competent mechanic like you in my area. Anyway, continue with these spectacular videos of yours! Kind regards, Fabio ;) p.s. ah, I forgot...I subscribed to your channel, obviously! ;)

[@tomsworkshopprojects]

Wow thanks Fabio! That’s very kind, I’m certainly no mechanic, and I’m doing a lot of this stuff for the first/second/third time, but I love the challenge and the skills I’m developing along the way. Appreciate the comment and glad to have you along for the ride!

[@pabsocs]

Tom's and RRC video in one day! it musty be Christmas

[@tomsworkshopprojects]

I know what I’m doing later then! His VFR series is getting me excited (and terrified) about doing my RVF once the ZX7R is done 😂

[@pabsocs]

you know youll smash it, cant wait for it all! happy Christmas to you and yours. thanks for the genuinely great content @@tomsworkshopprojects

[@terrycrawford1982]

Excellent Tom

[@markhowlett8070]

Another great video. Thank you.

[@andrewharrison8880]

Did you give the cylinder barrells a complete clean afterwards after your honing? Washing out with warm soapy water, its extremely important to ensure there absolutely no microscopic traces of metal after the honing. Really good attention to detail, liking these videos😂.

[@tomsworkshopprojects]

Cheers! Yeah they got a good clean, however they’ll be getting another proper clean and blow out before painting the outside which should make sure there’s no grinding residue left in there!

[@pasha12343]

Excellent work as usual 👍😎🙂

[@antonios2846]

Hello Tom... Fantastic update. It is so nice to see the great ZX-7R going back to its glory. I own a P4! Take care and have a great Xmas

[@tomsworkshopprojects]

Cheers! You too!

[@WhiteOutHunting]

nice work

[@Franz_giblet]

You didn’t mention in the video about positioning the gaps in the piston rings on the pistons, maybe you did it off camera? Good video though 👌🏻👌🏻

[@tomsworkshopprojects]

I haven’t really set them yet, but I will make a point when they go back in the cylinders, thanks for the heads up!

[@TheLarko10]

Noice work mate

[@andyb2311]

Very cool mate reeling enjoying this build, thinking now that a Kawasaki might be on the agenda in the next few yers for me to build

[@tomsworkshopprojects]

Cheers mate! Haha glad it’s giving you the Kwaka-bug 😂

[@eugenecussen3735]

Use the smaller knurled nut at the end of the micrometer...its calibrated as a ratchet stop for accurate readings

[@tomsworkshopprojects]

Thanks! Good to know what the ratchet bit is for!

[@pieterbrepoels6563]

What liquid do you use for aluminium cleaning in the ultra sonic

[@tomsworkshopprojects]

I’m still playing around with different fluids, I’ve tried Carbusonic which worked ok but you have to rinse them well afterwards. For the pistons I used brake cleaner diluted slightly with distilled water. Which worked quite well.

[@spent808]

There's a reason a ratchet adjuster exists on the end of your micrometer.

[@tomsworkshopprojects]

Very much learning, so any advice is welcome 🙏🏼

[@a8f235]

The videos are good and enjoyable, but it would be good to add some ambient noise, because it becomes overly quiet when you're not talking.

[@tomsworkshopprojects]

Yeah I’ve played around with that before, still working out the balance, my general sense is less is more, but I agree it can get a bit too quiet at times 😂

[@stephenmcqueen4029]

Please god, no music

[@a8f235]

@@stephenmcqueen4029 Point to where I stated music.