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wilz1234 This post is not being displayed .



wilz1234









Joined: 14 Jul 2010

Karma : Trackday TricksterJoined: 14 Jul 2010Karma :

Posted: 00:22 - 24 Apr 2012 Posted: 00:22 - 24 Apr 2012 Post subject: zxr 400 revival



Heres how my bike looked back in 2008 when I bought her, it's a 1992 ZXR 400 L:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/Untitled.png



Was running a bit rough and generally needed a tidy up so here goes.



Unfortunately I didn't have a camera at this point, but basically the only bit i dont have pictures of is stripping the whole bike down into bits, cleaning the engine, stripping it apart then replacing gearbox bearings and big end surface bearings and all seals down there.



New rings back on the pistons:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0068.jpg



New base gasket and rehoned cylinders back on:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0089.jpg



On the stand me and a mate knocked up one afternoon.

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0093.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0014-1.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0015-1.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0013-1.jpg



Just ignore the hammer:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0010.jpg



Freshly skimmed cylinder head:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0105.jpg



Reground valves:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0103.jpg



All the valves, springs, seals, collets etc back in:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0107.jpg



Rocker arms back in:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0113.jpg



Cam covers back in, with new chain. All the valve clearances were measured and luckily I only had to swap 2 of the shims around.

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0013.jpg



Forks stripped apart (never used those nikone seals in the end because they sent the wrong size)

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0028.jpg



New seals and oil, quick bit of polish:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0053.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0055.jpg



Bits got back from the powder coaters (wish they had masked of the places I told them to and put bolts in the holes):

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0059.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0062.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0071-1.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0070-1.jpg



New bearings for everything:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0075.jpg



New swingarm spindle from wemoto which was the right diameter but 23mm too long:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0076-1.jpg



Went to a turners to see if they would shorten it but because its hardened they wouldnt touch it. So took it into work and used the wire eroder to cut it down to the correct length:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0084-1.jpg



Et voila!:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0086-1.jpg



Headrace bearings:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0079-1.jpg



Some rubber:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0089-1.jpg



Frame/swingarm/suspension going back together:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0091-1.jpg



And the test fit of a cbr600rr tail fairing from ricambi weiss on ebay (would never ever use them again after the trouble i had with various fairings from them)

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0095.jpg

And yes, that is the dining room table



Back outside and ready to take the forks:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0100-1.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0101-1.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0102-1.jpg



Engine back in:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0106-1.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0107-1.jpg



Exhaust on...hmmmm stainless....

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0108.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0130.jpg



Fake pazzos, bobbins, renthal grips

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0150.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0157.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0159.jpg





Fairings arrived....good work ricambi weiss....not

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0165.jpg



Disks:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0170.jpg



Stripped paint from calipers:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0173.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0174.jpg



This looks a little more tarty xD

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0174.jpg





Seriously contemplated streetfightering it:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0179.jpg



Spacer machined up to allow a press fit 52mm(i think, cant remember now) end can:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0183.jpg



Mivv Silencer:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0187.jpg



Trail fitting fairings:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0190.jpg



Link to the first running video:

http://s944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/?action=view¤t=VIDEO0010.mp4



Tarty lines to match the tarty brakes

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0273.jpg



Set of samco hoses:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0276.jpg



DID chain and talon sprocket:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0280.jpg



Mocked up seat support:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0288.jpg



Mocked up undertray:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0289.jpg



Undertray finished:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0303.jpg



Some random teasers:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/Pic1.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/Pic6.jpg



Carbon goodies:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0321.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0322.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0325.jpg



New screen and mirrors:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0338.jpg



The 3 kawasakis i've had since passing my test reunited

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0348.jpg



Subframe off for chopping and powdercoating:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0351.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0352.jpg



Painting (thanks to a friend from work)

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0362.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0363.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0364.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0370.jpg



Bottoms done black and stickered up:

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0391.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0390.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0394.jpg



And finished, apart from the foam seat which i still dont like.

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0419.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0415.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0417.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0418.jpg

http://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0440.jpg





So if you're still awake after all that feel free to throw some comments/criticism my way. I don't normally post much here but it's nice to finally add my project xD

____________________

RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650 Did have this up on tjtuning but it appears that sites gone nowHeres how my bike looked back in 2008 when I bought her, it's a 1992 ZXR 400 L:Was running a bit rough and generally needed a tidy up so here goes.Unfortunately I didn't have a camera at this point, but basically the only bit i dont have pictures of is stripping the whole bike down into bits, cleaning the engine, stripping it apart then replacing gearbox bearings and big end surface bearings and all seals down there.New rings back on the pistons:New base gasket and rehoned cylinders back on:On the stand me and a mate knocked up one afternoon.Just ignore the hammer:Freshly skimmed cylinder head:Reground valves:All the valves, springs, seals, collets etc back in:Rocker arms back in:Cam covers back in, with new chain. All the valve clearances were measured and luckily I only had to swap 2 of the shims around.Forks stripped apart (never used those nikone seals in the end because they sent the wrong size)New seals and oil, quick bit of polish:Bits got back from the powder coaters (wish they had masked of the places I told them to and put bolts in the holes):New bearings for everything:New swingarm spindle from wemoto which was the right diameter but 23mm too long:Went to a turners to see if they would shorten it but because its hardened they wouldnt touch it. So took it into work and used the wire eroder to cut it down to the correct length:Et voila!:Headrace bearings:Some rubber:Frame/swingarm/suspension going back together:And the test fit of a cbr600rr tail fairing from ricambi weiss on ebay (would never ever use them again after the trouble i had with various fairings from them)And yes, that is the dining room tableBack outside and ready to take the forks:Engine back in:Exhaust on...hmmmm stainless....Fake pazzos, bobbins, renthal gripsFairings arrived....good work ricambi weiss....notDisks:Stripped paint from calipers:This looks a little more tarty xDSeriously contemplated streetfightering it:Spacer machined up to allow a press fit 52mm(i think, cant remember now) end can:Mivv Silencer:Trail fitting fairings:Link to the first running video:Tarty lines to match the tarty brakesSet of samco hoses:DID chain and talon sprocket:Mocked up seat support:Mocked up undertray:Undertray finished:Some random teasers:Carbon goodies:New screen and mirrors:The 3 kawasakis i've had since passing my test reunitedSubframe off for chopping and powdercoating:Painting (thanks to a friend from work)Bottoms done black and stickered up:And finished, apart from the foam seat which i still dont like.So if you're still awake after all that feel free to throw some comments/criticism my way. I don't normally post much here but it's nice to finally add my project xD

CaNsA This post is not being displayed .



CaNsA









Joined: 02 Jan 2008

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Posted: 00:45 - 24 Apr 2012 Posted: 00:45 - 24 Apr 2012 Post subject: That is bloody awesome dude.



I am seriously wanting that sort of engine work carried out on mine.



Have you posted this up on zxrworld.co.uk forums?

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wilz1234 This post is not being displayed .



wilz1234









Joined: 14 Jul 2010

Karma : Trackday TricksterJoined: 14 Jul 2010Karma :

Posted: 00:50 - 24 Apr 2012 Posted: 00:50 - 24 Apr 2012 Post subject: I was going to but everytime I signed up last year my account was getting deleted.



Its still work in progress really. Wants a good carb set up and possibly lowering the seat unit a little so the seat position isn't so high/uncomfortable

____________________

RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

CaNsA This post is not being displayed .



CaNsA









Joined: 02 Jan 2008

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Posted: 00:52 - 24 Apr 2012 Posted: 00:52 - 24 Apr 2012 Post subject: We had loadsa spammers giving us hassle.



Should be sorted now, if you sign up ill pop a note on your account.

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wilz1234 This post is not being displayed .



wilz1234









Joined: 14 Jul 2010

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Posted: 00:54 - 24 Apr 2012 Posted: 00:54 - 24 Apr 2012 Post subject: Cheers man. I'll get on that tomorrow

____________________

RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

haroman666 This post is not being displayed .



haroman666









Joined: 17 Sep 2008

Karma : World Chat ChampionJoined: 17 Sep 2008Karma :

Posted: 01:12 - 24 Apr 2012 Posted: 01:12 - 24 Apr 2012 Post subject:



I'd love to have the dedication and monies to do that.



One day maybe...

____________________

The mistresses: 2000 Honda CBR600f, 2000 Honda VTR1000 Frickin' sweet build dude!I'd love to have the dedication and monies to do that.One day maybe...

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Bike Bunker









Joined: 28 Oct 2010

Karma : World Chat ChampionJoined: 28 Oct 2010Karma :

Posted: 02:12 - 24 Apr 2012 Posted: 02:12 - 24 Apr 2012 Post subject: Very awesome build... really hope to go into this much detail on mine sometime, only ever manage to do 1 thing at a time





as for nikone seals i fitted those to mine the one failed the week after against all the belief i had they would be ok, kawasaki cradley worked out best even for £20 instead of 6

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fager









Joined: 24 Apr 2012

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Posted: 09:58 - 24 Apr 2012 Posted: 09:58 - 24 Apr 2012 Post subject:



http://www.nlmlol.info/g.gif I was going to but everytime I signed up last year my account was getting deleted.

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chris-red









Joined: 21 Sep 2005

Karma : Have you considered a TDM?Joined: 21 Sep 2005Karma :

Posted: 10:03 - 24 Apr 2012 Posted: 10:03 - 24 Apr 2012 Post subject:

____________________

Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.

Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.

WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything. Nice work the only thing I will say is the tail unit is a tad too long, I think.

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kentpunkster









Joined: 24 Jan 2011

Karma : Two Stroke SnifferJoined: 24 Jan 2011Karma :

Posted: 14:07 - 24 Apr 2012 Posted: 14:07 - 24 Apr 2012 Post subject: Top job!!!

highland biker This post is not being displayed .



highland biker









Joined: 17 Nov 2007

Karma : Spanner MonkeyJoined: 17 Nov 2007Karma :

Posted: 14:17 - 24 Apr 2012 Posted: 14:17 - 24 Apr 2012 Post subject:

____________________

past: klx 250, cbr125, SRAD 600, cbr600rr

present: uber practial r1 for the daily commute good work sir! you definately have some skills

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Hetzer









Joined: 19 Feb 2007

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Posted: 14:39 - 24 Apr 2012 Posted: 14:39 - 24 Apr 2012 Post subject:

____________________

"There's the horizon! Ride hard, ride fast and cut down all who stand in your way!" Seriously impressive.

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wilz1234 This post is not being displayed .



wilz1234









Joined: 14 Jul 2010

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Posted: 15:06 - 24 Apr 2012 Posted: 15:06 - 24 Apr 2012 Post subject: Thanks guys!



If anyone has any experience setting up carbs properly I'd love a hand sometime. I'd imagine i could balance it myself, but wouldnt really know where to start in order to get the mixture right other than spark plug colour

____________________

RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

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Moxey









Joined: 11 May 2011

Karma : World Chat ChampionJoined: 11 May 2011Karma :

Posted: 21:01 - 24 Apr 2012 Posted: 21:01 - 24 Apr 2012 Post subject:



Two of my mates have ZXR 400s a H and a L both look awesome but I see from this the L does suit a modern tail unit (only qualm is it looks like a ducks beak if you envision it without the rest of the bike)



Current: 02 FZS 100, 77 CG 125 & 91 Yamaha XV 250

'I was too busy paying attention to pay attention' ____________________Current: 02 FZS 100,& 91 Yamaha XV 250 Some Bike Pics... 'I was too busy paying attention to pay attention' Very nice workTwo of my mates have ZXR 400s a H and a L both look awesome but I see from this the L does suit a modern tail unit (only qualm is it looks like a ducks beak if you envision it without the rest of the bike)

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Fowlersrs









Joined: 30 Mar 2012

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Posted: 21:05 - 24 Apr 2012 Posted: 21:05 - 24 Apr 2012 Post subject: looks like a really nice job mate, uve covered every aspect of the bike in nice detail, can I ask how much uve spent? on the original bike and bits uve added too it?

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Benson_JV









Joined: 04 May 2010

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Posted: 22:07 - 24 Apr 2012 Posted: 22:07 - 24 Apr 2012 Post subject:

____________________

Willson - "If you go out on that CBR600 in the winter, you're going to do more miles on your side than on your wheels."

Riding: CBR600FW Driving: Audi A6

Previous Bikes: '96 Bandit 600, '96 GPz305 Very. Nice.

wilz1234 This post is not being displayed .



wilz1234









Joined: 14 Jul 2010

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Posted: 22:27 - 24 Apr 2012 Posted: 22:27 - 24 Apr 2012 Post subject: Fowlersrs wrote: looks like a really nice job mate, uve covered every aspect of the bike in nice detail, can I ask how much uve spent? on the original bike and bits uve added too it?



Originally I got the bike for £1200, and then during my gap year while I did it up I probably spent in the region of £2k. Seems a lot but when you think theres nearly £500 of genuine kawasaki parts just in the engine alone

____________________

RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

wilz1234 This post is not being displayed .



wilz1234









Joined: 14 Jul 2010

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Posted: 22:29 - 24 Apr 2012 Posted: 22:29 - 24 Apr 2012 Post subject: Tim.. wrote:



Have some though Nice work...but for me the seat unit doesnt fit the style of the rest of the bikeHave somethough



I think I must have a thing for modern looking bikes but I've loved the zxr ever since I got one xD

____________________

RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

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CaNsA









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Posted: 22:36 - 24 Apr 2012 Posted: 22:36 - 24 Apr 2012 Post subject: *pokes with stick*

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Gazza M









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Posted: 22:43 - 24 Apr 2012 Posted: 22:43 - 24 Apr 2012 Post subject: sweet as. i'd love to do something like this, onyl time and monez atm are a bitch!



i actually quite like the look of the green/white gradient, continue that to the tailpiece and i reckon it'd look awesome!

____________________

Past: '07 YBR125, '00 GPZ500S, '99 ZRX1100, '98 CBR600 track bike, '97 ZX9R

Present: '05 R6 track bike, 140 pit bike

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wildmark13









Joined: 24 Apr 2012

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Posted: 23:56 - 25 Apr 2012 Posted: 23:56 - 25 Apr 2012 Post subject: great project

____________________

Current Bikes: Honda CRF 250R, Honda CB500R

Mod 2 (pass) 14/05/12. What a fantastic project, you have some great talent and connections. I have a couple of friends with zxr400s, and they do make me quite envious. I hope you enjoy riding it as much as I enjoyed your posts!

Old Thread Alert!



There is a gap of 1 year, 236 days between these two posts...

wilz1234 This post is not being displayed .



wilz1234









Joined: 14 Jul 2010

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Posted: 13:53 - 18 Dec 2013 Posted: 13:53 - 18 Dec 2013 Post subject:



I'm going to go back to a standard looking zxr shape with no pointy back end. Anyone know where I could find a solo seat like this?:



http://www.motorcyclespecs.co.za/Gallery/Kawasaki%20ZXR400%2093%20%201.jpg

____________________

RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650 Been over a year now and I haven't really had much use out of her. I think part of the reason is that the new seat position is terrible.I'm going to go back to a standard looking zxr shape with no pointy back end. Anyone know where I could find a solo seat like this?:

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Billing









Joined: 12 Mar 2009

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Posted: 05:15 - 19 Dec 2013 Posted: 05:15 - 19 Dec 2013 Post subject: http://item.mobileweb.ebay.co.uk/viewitem?sbk=1&nav=SEARCH&itemId=280953884545



this any good mate? Cant be too hard to do the cut out for the tail light.

____________________

'84 TS50X, '91 TZR125, '89 CBR400RR, '91 VFR400R NC30, '98 R1

"Hey copernicus! Why don't you navigate yourself to the back of the line with your feet and stand there with your shit."

BCF Eastern members map here ---> g.co/maps/2tm8b PM me to be added to it! this any good mate? Cant be too hard to do the cut out for the tail light.

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Old Thread Alert!



The last post was made 6 years, 276 days ago. Instead of replying here, would creating a new thread be more useful?