ZZR1200 spark plug well

[SeaPuP]

Decided to take a look at the 05 ZZR1200
for general maintenance Yesterday
since the bike sounds alittle quiet.

Going to readjust the air/fuel mixture screws,
reinstall the carb shimms,
resync the carbs, put on a new set of
CRA's , Clean what I can not see, and look
for anything that looks unusual.

***The set of Metzlers that Helodoc ****
*** gave me have lasted 8,000 + ****
***I could go longer but I'm going ****
*** to change them out anyways ****
*** Many Thanks To HeloDoc ****







1st thing found

#2 spark well had alot of oil in it, the spark plug boot had oil up in it
too. I took it apart, cleaned it and reassembled it.
****** spark plug wells filling with oil appears normal*****
****** since it happens all the time *****
****** Its the first thing I look for when the bike *****
****** seems to run quiet *****

Is that little ceramic piece inside the spark plug boot a fuse???

[sillyhillbilly]

cant read your thread very well

with all the antics of your thread it is hard to keep track of your topic

that said the oil in the spark plug holes is from the valve cover plug hole seals, change them pronto, with just a little more than you think of oil loss you could be low on oil and cause crank.rod bearing failure,
operating this style engine on 1/2 quart low can over some time bring about issues that will result in thrown rod out the caseings
change those spark plug holes seals/gaskets, they get hard with age & from the heat, I had to replace mine for the same reason at 3 yrs with 28k on the clocks,
I had a buddy oput in phoenix that had rod bearing go down after a hard day of twisties in the mountains, from this issue of oil loss, when he got home, he heard a slight noise, nothing major at this point, or so he thought, he didnt ride it again for a week and when he started it up, the noise was louder and he knew right then what it was, he pulled out motor and split cases and wholla number 3 rod bearing was down, nothing you could hear per say when riding when the damage was done, but after letting the oil settle for those days and starting it with some dryness on the bearing he said it was obvous, but again nothing loud or heavy, he said he was hearing the piston gently hitting the head due to loss of tolerance of the rod bearing, all from loss of oil thru a bda set of spark plug hole seals/gaskets

[SeaPuP]

Your buddy must have never checked his oil sight glass,
I check mine religiously before every ride while the bike is on
the center stand. I have 46,000 miles on my 05 and
she runs fine

thanks for the post tho.

[1KPerDay]

If you haven't replaced the little figure 8 spark plug well gaskets, do so. They're cheap and will cause the leakage you describe. If that doesn't fix it you might have a porous head or a warped valve cover. If it doesn't bother you that's fine. However, the spark plug gasket things are a cheap thing to try.

Mine went about 15K or so, replaced them, no trouble.

[stryker]

i had one original 1 leak early on

i replaced them. next time i was in there like 10 grand later i din't remember to buy spares so i put a thin......really thiiiiinnnn coating of hi temp sealant on them. have not leaked since and i've been in there twice more since each time just reapplying sealant and have no leaks.

i just put plugs in and wells still dry

like 40 k on bike now

[SeaPuP]

Awhile back another happy ZZR1200 owner posted that
he had occasional oil in his spark plug wells and replaced
the o rings to have a different o ring leak in a different well.
I took it that these things leak even with replacements.

[1KPerDay]

They shouldn't... if he installed them correctly.

[Eeyore]

WHen I had my ZZR I had the same problem a couple of times and since I HATE Oil leaks / seaps .. I started replacing the O-Rings every Valve Adjustement which I did every 15,000 miles. It ran fantastic for the 45,000 + mile I put on Her and I did not ride Her lightly. She also so the Drag Strip on MANY occasions and was still runnig fantastic when I sold her. I ran full synth always and kept a good eye on the oil level ..

Just spend the extra few bucks and replace the O-Rings .. Your ZZR is WORTH it ..

S

[ajsenol]

what's the quickest way to get that valve cover off? I'm replacing my spark plug gaskets, and the throttle cables are smack dab in the middle. Do these things have a quick connect?

[mehush]

It was soo long ago, but I think I took the cables loose from the twist grip. Could be wrong though.

[slayman]

I replaced the gaskets recently but I had the carbs off for service. Getting the cover off requires a lift twist rotate lift sort of motion. I'm not sure you could do that with the cables connected to the carbs.

[BillDownUnder]

Removing the coils makes it a bit easier.

[Moise]

I wouldn't like to do the inlets with the carbs on. It has been a few years now, but it was dead easy with the carbs off.

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[BillDownUnder]

I wouldn't like to do the inlets with the carbs on. It has been a few years now, but it was dead easy with the carbs off.

That is what the manual recommends as well.

[ajsenol]

so, you unplug the carbs and swing them up and out of the way?