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ZZR600 re-build

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Wonko The Sane
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PostPosted: 13:24 - 28 Jun 2014    Post subject: ZZR600 re-build Reply with quote

So, on friday 13th this happened

https://i860.photobucket.com/albums/ab164/yorkshiresheep/Motorbike%20crash%20and%20restoration/photocopy.jpg

The chap in the yellow high vis is a cyclist who saw it and stopped to offer as a witness - happens to work for a personal injury legal firm…


Got some parts on order and expecting a cheque from the insurance next week.

Wanting to do running repairs to be able to be able to use the bike for getting to and from work while I acquire panels and find who can paint them for me.
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PostPosted: 16:53 - 28 Jun 2014    Post subject: Reply with quote

Hit from behind whilst stationary, I'm guessing?
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Wonko The Sane
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PostPosted: 18:06 - 28 Jun 2014    Post subject: Reply with quote

Crash thread here:

https://www.bikechatforums.com/viewtopic.php?t=291211
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Wonko The Sane
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PostPosted: 17:28 - 29 Jun 2014    Post subject: Reply with quote

So, just as I've decided to stick with genuine Kawasaki second hand fairings someone comes along on the ZZR forum and recommends the ZZR400 kits from china: https://www.aliexpress.com/item/Free-shipping-For-Kawasaki-ZZR400-1993-2003-ZZR-400-93-97-ZZR-400-93-03-ZZR/1872594976.html

Apparently the 400 was the same frame and body but differed mechanically so the kit should fit…

Which option to take, this kit is the colour I want so would only need to paint the current tank (which I could do myself) or stick with the current plan of acquire panels via e-bay.
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Kickstart
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PostPosted: 17:41 - 29 Jun 2014    Post subject: Reply with quote

Hi

Original panels in decent condition and in the right colour via Ebay will take quite a while to find and are not likely to be cheap. Many of those for sale will be no better than your current panels.

If that really is the panels for a late ZZR400 (never seen a late shape one, all the ZZR400s I have seen have been the earlier ones with loads of differences) then at that price well worth thinking about. Although that does appear to be the price per set if you buy 8 or more sets so not sure what the individual price is (or if you have ~£2000 to buy loads and sell the extras on).

Another option would be to get your current fairing repaired / resprayed.

All the best

Keith
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Wonko The Sane
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PostPosted: 18:35 - 29 Jun 2014    Post subject: Reply with quote

sticking with Kwak panels

Had seen some chinese panels unpainted so have been planning on a paint job anyway (had been planning it before the incident)

Parts damaged in the crash are as follows:

Right hand crash bung (bent)
Right hand belly pan (cracked by above)
Left hand exhaust (bent)
Main fairing
main dash in-fill
possibly right hand dash in-fill
front mudguard
rear hugger
double bubble screen

left hand tail fairing had a damaged mount so might as well sort and the stock screen got fitted yesterday.

Parts ordered:
Full belly pan
Left hand exhaust
fairing side mount mount (have a main in spare)
Main dash in-fill
Right hand dash in-fill
mudguard (spares box)
rear hugger
fairing bolt kit
left hand fairing
rear shock absorber

the guy in the mail room at work is going to hate me!
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Wonko The Sane
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PostPosted: 21:32 - 30 Jun 2014    Post subject: Reply with quote

First arrivals today:

https://i860.photobucket.com/albums/ab164/yorkshiresheep/Motorbike%20crash%20and%20restoration/photocopy3.jpg

Two pieces of dashboard (left hand side was unscathed) unfortunately the dash surround has at some point been painted so I'll need to sand it back and perhaps paint it satin black (fancied doing this anyway

https://i860.photobucket.com/albums/ab164/yorkshiresheep/Motorbike%20crash%20and%20restoration/photocopy2.jpg

I got into work late due to taking my daughter to nursery, I arrived to find an exhaust laid across my desk, it was a bit rustier on the link pipes than it looked in the photo so it's now been cleaned up, sanded a bit and I decided due to the various knocks and scrapes on my existing exhaust and the new one that I'd paint them black.

here's hoping the 600degree temperature that Hammerite claim is sufficient.
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Arfa__
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PostPosted: 13:55 - 01 Jul 2014    Post subject: Reply with quote

Yes, ZZR400 is the same. Well, there's:-

'90-92 ZZR600D = ZZR400K
'93-01 ZZR600E = ZZR400N

The latter has the ram air intake and very different styling all round.
Otherwise the only real differences between the 400 and 600's were the pistons and associated bits. The 400's were a sleeved down version of the 600 - less power and heavier - doh! That and other minor bits like CDI (with Jap restrictor), clocks in Km etc.

Just flogged an old '93 ZZR400 for £750...
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Wonko The Sane
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PostPosted: 22:33 - 01 Jul 2014    Post subject: Reply with quote

started spraying the dash surrounds (one was already painted a horrid colour) in primer, was working too late into the evening and a bit of the primer has gone orange-y peel-y but I was going to be sanding it back anyway.

new arrivals of parts are YSS shock (couldn't afford Hagon as got YSS at trade price) rear brake pads and fairing bolts.

Also rear hugger from M&P which isn't the same shape as the old one but looks as though it should still fit.

Second coat on the exhausts, bit of a sand back and final coat.

Need to get a torque wrench before fitting the new shock, thinking best to do that and the hugger before re-fitting the exhausts.

Realised from having the bike on the centre stand that I'm low on oil, not dangerously but just below the min mark, there's an 0 ring missing from the filler cap so it's been weeping out, need to get an 0 ring and some oil.
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Wonko The Sane
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PostPosted: 22:15 - 16 Sep 2014    Post subject: Reply with quote

Whoops, forgot about this thread,

Since the previous post I have a full set of panels waiting to be painted, just need to swap the fuel tank across / check the one I've bought holds fuel and get that painted - can't decide which.

Fitted the shock, fitted a touring screen and had new tyres fitted to the powder coated wheels.

https://i860.photobucket.com/albums/ab164/yorkshiresheep/Motorbike%20crash%20and%20restoration/photo-10.jpg
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Wonko The Sane
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PostPosted: 19:11 - 11 Oct 2014    Post subject: Reply with quote

With a fair bit of help from Snoosnoo we've got it pretty much finished!

https://i860.photobucket.com/albums/ab164/yorkshiresheep/Motorbike%20crash%20and%20restoration/photocopy2-1.jpg
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beardface
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PostPosted: 15:46 - 14 Oct 2014    Post subject: Reply with quote

Nice, glad to see it looking like a bike again Cool
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Wonko The Sane
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PostPosted: 17:59 - 14 Oct 2014    Post subject: Reply with quote

Really enjoying the lack of rattling when going over rough bits of road,

It's also nicer to ride having had the restrictors out, however it had just come back from the garage having had the timing and clearances checked, carbs cleaned and balanced etc.
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