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| wilz1234 |
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 wilz1234 Trackday Trickster

Joined: 14 Jul 2010 Karma :  
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 Posted: 23:22 - 23 Apr 2012 Post subject: zxr 400 revival |
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Did have this up on tjtuning but it appears that sites gone now
Heres how my bike looked back in 2008 when I bought her, it's a 1992 ZXR 400 L:
https://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:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0068.jpg
New base gasket and rehoned cylinders back on:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0089.jpg
On the stand me and a mate knocked up one afternoon.
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0093.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0014-1.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0015-1.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0013-1.jpg
Just ignore the hammer:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0010.jpg
Freshly skimmed cylinder head:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0105.jpg
Reground valves:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0103.jpg
All the valves, springs, seals, collets etc back in:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0107.jpg
Rocker arms back in:
https://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.
https://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)
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0028.jpg
New seals and oil, quick bit of polish:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0053.jpg
https://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):
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0059.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0062.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0071-1.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0070-1.jpg
New bearings for everything:
https://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:
https://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:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0084-1.jpg
Et voila!:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0086-1.jpg
Headrace bearings:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0079-1.jpg
Some rubber:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0089-1.jpg
Frame/swingarm/suspension going back together:
https://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)
https://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:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0100-1.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0101-1.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0102-1.jpg
Engine back in:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0106-1.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0107-1.jpg
Exhaust on...hmmmm stainless....
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0108.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0130.jpg
Fake pazzos, bobbins, renthal grips
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0150.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0157.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0159.jpg
Fairings arrived....good work ricambi weiss....not
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0165.jpg
Disks:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0170.jpg
Stripped paint from calipers:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0173.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0174.jpg
This looks a little more tarty xD
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0174.jpg
Seriously contemplated streetfightering it:
https://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:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0183.jpg
Mivv Silencer:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0187.jpg
Trail fitting fairings:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0190.jpg
Link to the first running video:
https://s944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/?action=view¤t=VIDEO0010.mp4
Tarty lines to match the tarty brakes
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0273.jpg
Set of samco hoses:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0276.jpg
DID chain and talon sprocket:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0280.jpg
Mocked up seat support:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0288.jpg
Mocked up undertray:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0289.jpg
Undertray finished:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0303.jpg
Some random teasers:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/Pic1.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/Pic6.jpg
Carbon goodies:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0321.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0322.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0325.jpg
New screen and mirrors:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0338.jpg
The 3 kawasakis i've had since passing my test reunited
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0348.jpg
Subframe off for chopping and powdercoating:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0351.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0352.jpg
Painting (thanks to a friend from work)
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0362.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0363.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0364.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0370.jpg
Bottoms done black and stickered up:
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0391.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0390.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0394.jpg
And finished, apart from the foam seat which i still dont like.
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0419.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0415.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0417.jpg
https://i944.photobucket.com/albums/ad290/wilz1234/zxr%20400%20project/IMAG0418.jpg
https://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 |
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| CaNsA |
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 CaNsA Super Spammer

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| wilz1234 |
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 wilz1234 Trackday Trickster

Joined: 14 Jul 2010 Karma :  
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| CaNsA |
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 CaNsA Super Spammer

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| wilz1234 |
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 wilz1234 Trackday Trickster

Joined: 14 Jul 2010 Karma :  
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| haroman666 |
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 haroman666 World Chat Champion

Joined: 17 Sep 2008 Karma :   
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 Posted: 00:12 - 24 Apr 2012 Post subject: |
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Frickin' sweet build dude!
I'd love to have the dedication and monies to do that.
One day maybe...  ____________________ The mistresses: 2000 Honda CBR600f, 2000 Honda VTR1000 |
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| Bike Bunker |
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 Bike Bunker World Chat Champion

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| fager |
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 fager L Plate Warrior
Joined: 24 Apr 2012 Karma :  
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 Posted: 08:58 - 24 Apr 2012 Post subject: |
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I was going to but everytime I signed up last year my account was getting deleted.
https://www.nlmlol.info/g.gif |
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| chris-red |
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 chris-red Have you considered a TDM?

Joined: 21 Sep 2005 Karma :   
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 Posted: 09:03 - 24 Apr 2012 Post subject: |
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Nice work the only thing I will say is the tail unit is a tad too long, I think.  ____________________ 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. |
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| kentpunkster |
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 kentpunkster Two Stroke Sniffer

Joined: 24 Jan 2011 Karma :    
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 Posted: 13:07 - 24 Apr 2012 Post subject: |
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| highland biker |
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 highland biker Spanner Monkey
Joined: 17 Nov 2007 Karma :     
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 Posted: 13:17 - 24 Apr 2012 Post subject: |
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good work sir! you definately have some skills  ____________________ past: klx 250, cbr125, SRAD 600, cbr600rr
present: uber practial r1 for the daily commute |
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| Hetzer |
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 Hetzer Super Spammer

Joined: 19 Feb 2007 Karma :     
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 Posted: 13:39 - 24 Apr 2012 Post subject: |
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Seriously impressive.  ____________________ "There's the horizon! Ride hard, ride fast and cut down all who stand in your way!" |
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| wilz1234 |
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 wilz1234 Trackday Trickster

Joined: 14 Jul 2010 Karma :  
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| Moxey |
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 Moxey World Chat Champion

Joined: 11 May 2011 Karma :   
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 Posted: 20:01 - 24 Apr 2012 Post subject: |
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Very nice work
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 1000 & 51 Moto Guzzi California Some Bike Pics...
'I was too busy paying attention to pay attention' |
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 Fowlersrs World Chat Champion

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 Aff World Chat Champion

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| Tim.. |
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 Tim.. World Chat Champion

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| Benson_JV |
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 Benson_JV World Chat Champion
Joined: 04 May 2010 Karma :  
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 Posted: 21:07 - 24 Apr 2012 Post subject: |
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Very. Nice.  ____________________ 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 |
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| wilz1234 |
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 wilz1234 Trackday Trickster

Joined: 14 Jul 2010 Karma :  
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| wilz1234 |
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 wilz1234 Trackday Trickster

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| CaNsA |
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 CaNsA Super Spammer

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| Gazza M |
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 Gazza M Crazy Courier

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| wildmark13 |
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 wildmark13 Derestricted Danger

Joined: 24 Apr 2012 Karma :   
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 Posted: 22:56 - 25 Apr 2012 Post subject: great project |
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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!  ____________________ Current Bikes: Honda CRF 250R, Honda CB500R
Mod 2 (pass) 14/05/12. |
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Old Thread Alert!
There is a gap of 1 year, 236 days between these two posts... |
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| wilz1234 |
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 wilz1234 Trackday Trickster

Joined: 14 Jul 2010 Karma :  
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 Posted: 12:53 - 18 Dec 2013 Post subject: |
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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?:
https://www.motorcyclespecs.co.za/Gallery/Kawasaki%20ZXR400%2093%20%201.jpg ____________________ RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650 |
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| Billing |
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 Billing World Chat Champion

Joined: 12 Mar 2009 Karma :    
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 Posted: 04:15 - 19 Dec 2013 Post subject: |
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https://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! |
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Old Thread Alert!
The last post was made 12 years, 2 days ago. Instead of replying here, would creating a new thread be more useful? |
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