My ZX6R J1 race bike project

[Red Devil]

[P.]

Definitely enjoying this. The can has come out really well

[Red Devil]

[Red Devil]

Braided lines turned up today:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121102_203620.jpg

These came last week as well, air filter, oil filter, head race bearings & full set of seals for the front brakes:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121026_184418.jpg

Brings the total spend on parts to around £165ish + autosol and a few other bits which cost around £15.
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Red Devil]

Finished one of the brakes today, cheers to BoshBish for giving me a hand to get it done quicker.

Pistons cleaned up:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121103_154334.jpg

New seals in greased up:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121103_155931.jpg

And the finished product, looking much better now!

https://i1061.photobucket.com/albums/t468/RedDevil92/20121103_160327.jpg

Stripped the other caliper down now as well after using one of the braided lines to push the pistons out (I pushed a couple in too far first time I tried to take them out as I forgot to pump them out the first time). Once again thanks to DickBasher for sorting me out some brake fluid to do it!
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Red Devil]

The rest of the exhaust system is almost done and also finished the other caliper so the brakes are all good now just need fitting with the braided lines after the forks/head stock are done.

Exhaust before:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121023_195445.jpg

After:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121104_130642.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20121104_130733.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20121104_130757.jpg
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[.Bishbash.]

You know, I would have rated you interesting if it weren't for these play on words on my username!

[Red Devil]

[0l0dom0l0]

[Red Devil]

Progress has been slow recently due to lack of fund for new parts and waiting for the shock to be done, picked up the shock today though so could crack on!

Shock looking a bit cleaner after a full service including being revalved, cost me £120 bringing the total spend so far to £300:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121117_142022.jpg

Stripped down the suspension linkage and it wasn't looking too good so gave every a clean. Removed the old (now black) grease and chucked loads of fresh grease on to keep it all moving nice and smooth.

https://i1061.photobucket.com/albums/t468/RedDevil92/20121117_150214.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20121117_160241.jpg

Shock, linkage & swing arm back in place:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121117_173300.jpg

Starting to resemble a bike again with the subframe back on:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121117_174146.jpg

Now I could pop the back up on the paddock stand and put the axle stands under the engine to start removing parts from the front. Forks and head stock are are now off, the forks will be going off for rebuilding when I come back from Egypt next weekend.

The notch in the head stock felt horrendous when I got the forks off, glad I'm sorting that out!

https://i1061.photobucket.com/albums/t468/RedDevil92/20121117_182639.jpg


____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[.Bishbash.]

That rear shock looks so much better, but of course I hope it works better now it's done.

Are you getting him to do the front ones? If so, when?
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Current bike - GSX-R1000 k8

[Red Devil]

[.Bishbash.]

[Red Devil]

Next time we go to brands with the bike fully set up I want 54s minimum and am aiming for 53s oh yeah early dates for next year mate are Mallory Park 27th January and 16th at Cadwell, let me know if you want to come.
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Red Devil]

Update time, not much to report though!

Crash protectors, chain, race seat foam and spark plugs turned up last week, total spend so far is now £516.

Crash protectors - ordered some R&G ones as I need the replacement coolant bottle with the hole in the middle, I have to send the bottle back as it has a snapped connection so that hasn't been fitted yet. My mate is a CAD engineer so I got him to knock me up a set of replica crash bobbins as spares, this is one of them next to the proper R&G version:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121206_204553.jpg
https://i1061.photobucket.com/albums/t468/RedDevil92/20121206_204618.jpg

He is also going to make me crash protectors for the forks & swing arm, custom pegs & brackets to improve ground clearance and a race fuel cap.

I stripped down my seat of the old leather and foam to this:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121107_211314.jpg

Sprayed it with primer:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121201_164402.jpg

Then black paint to match the bike as some of the plastic is now going to be on show:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121202_154234.jpg

The reason for doing this is because I am replacing the standard foam with race foam to drop me into the bike a bit more and allow me to slide on the seat more easily. I ordered some 20mm foam which cost me £30 for a 500x500mm sheet (expensive I know) and managed to waste it! I cut it up as it wouldn't bend to the shape of the seat and stay there but it looked like such a bodge job I decided to rip it off.

I am going to order some 10mm foam instead which should bend more easily and am going to use a couple of bolts to hold it in place, I'll post up pictures when it's done. With the new foam I will be sat around 70mm lower on the bike and I had a quick trial when I fitted the 20mm foam the first time and really liked the new position. Feels like it will be much easier to get tucked in and angles you more towards the front of the bike but the real test will be when I ride on track for the first time.

Stripped and cleaned the carbs (managed to spray carb spray in my eyes in the process of this, wasn't good!):

https://i1061.photobucket.com/albums/t468/RedDevil92/20121201_162920.jpg

The spark plugs didn't look that bad considering these have probably done the same amount of miles as the bike (16K):

https://i1061.photobucket.com/albums/t468/RedDevil92/20121201_180854.jpg

New iridium plugs put in, having a hard time trying to refit the coils though as they just don't seem to want to go back in!

X-ring DID chain:

https://i1061.photobucket.com/albums/t468/RedDevil92/20121203_190425.jpg

New head racing bearings are now in as well, feels nice and smooth!

More updates to follow as I go along
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Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[Eddie Hitler]

There's something so satisfying opening a D.I.D chain wrapper. Maybe finding a gorgeous new chain perfectly lubed, with a little packet of lube for the split link rings.

... I'm getting a hard-on.

[Red Devil]

[Eddie Hitler]

So happy you feel that way. We're not alone.

[garth]

Have you got the same kind of spastic coils as the 9r, where they're essentially on the spark plug caps?

Good idea until the seals fail and they fill up with water...!

[Red Devil]

Yeah the coil is built into the top of the spark plug cap with a seal just below the coil cap. Won't go back in even with some 'gentle' persuation with a hammer, doing my head in!
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[garth]

Check you haven't got the screw on caps on the new spark plugs, and put a bit of silicone round the rubber on the caps.

[0l0dom0l0]

[Red Devil]

Looks worse in that picture due to the flash, this is a picture of all 4

https://i1061.photobucket.com/albums/t468/RedDevil92/20121201_182404.jpg
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing

[0l0dom0l0]

Ahh yeah.

You'd deffo get a few more horses by richening it up though.
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CBT Passed: 30/08/2009, Theory Passed: 31/08/2010, Mod 1 Passed: 6/9/2010, Mod 2 Passed: 13/09/2010. Restriction ended 13/09/2012.

Bikes: 2007 Derbi GPR 50, 1998 Yamaha Fazer 600 (written off), 2002 Yamaha Fazer 600, 1994 CBR 600F, 2003 Triumph Daytona 600, Kawasaki ZX6R J1.....Current: 2006 Yamaha FZ6, 1998 Suzuki TL1000R and a Honda VFR 400 NC30.

[Red Devil]

What is the best way to richen it up?
____________________
Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
www.facebook.com/MattJohnstonRacing