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zxr 400 revival

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wilz1234
Trackday Trickster



Joined: 14 Jul 2010
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PostPosted: 23:22 - 23 Apr 2012    Post subject: zxr 400 revival Reply with quote

Did have this up on tjtuning but it appears that sites gone now Sad

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 Very Happy

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
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CaNsA
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Joined: 02 Jan 2008
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PostPosted: 23:45 - 23 Apr 2012    Post subject: Reply with quote

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
Trackday Trickster



Joined: 14 Jul 2010
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PostPosted: 23:50 - 23 Apr 2012    Post subject: Reply with quote

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
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CaNsA
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PostPosted: 23:52 - 23 Apr 2012    Post subject: Reply with quote

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
Trackday Trickster



Joined: 14 Jul 2010
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PostPosted: 23:54 - 23 Apr 2012    Post subject: Reply with quote

Cheers man. I'll get on that tomorrow
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haroman666
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Joined: 17 Sep 2008
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PostPosted: 00:12 - 24 Apr 2012    Post subject: Reply with quote

Frickin' sweet build dude!

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

One day maybe... Razz
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Bike Bunker
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Joined: 28 Oct 2010
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PostPosted: 01:12 - 24 Apr 2012    Post subject: Reply with quote

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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chris-red
Have you considered a TDM?



Joined: 21 Sep 2005
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PostPosted: 09:03 - 24 Apr 2012    Post subject: Reply with quote

Nice work the only thing I will say is the tail unit is a tad too long, I think. Thumbs Up
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kentpunkster
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Joined: 24 Jan 2011
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PostPosted: 13:07 - 24 Apr 2012    Post subject: Reply with quote

Top job!!! Very Happy Very Happy Very Happy
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highland biker
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Joined: 17 Nov 2007
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PostPosted: 13:17 - 24 Apr 2012    Post subject: Reply with quote

good work sir! you definately have some skills Thumbs Up
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Hetzer
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PostPosted: 13:39 - 24 Apr 2012    Post subject: Reply with quote

Seriously impressive. Thumbs Up
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wilz1234
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Joined: 14 Jul 2010
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PostPosted: 14:06 - 24 Apr 2012    Post subject: Reply with quote

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
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Moxey
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PostPosted: 20:01 - 24 Apr 2012    Post subject: Reply with quote

Very nice work Thumbs Up

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)
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Fowlersrs
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PostPosted: 20:05 - 24 Apr 2012    Post subject: Reply with quote

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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Aff
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PostPosted: 20:13 - 24 Apr 2012    Post subject: Reply with quote

Very nice job, well done Thumbs Up
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Tim..
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PostPosted: 20:34 - 24 Apr 2012    Post subject: Reply with quote

Nice work...but for me the seat unit doesnt fit the style of the rest of the bike

Have some Thumbs Up Karma though Wink
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Benson_JV
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PostPosted: 21:07 - 24 Apr 2012    Post subject: Reply with quote

Very. Nice. Thumbs Up
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wilz1234
Trackday Trickster



Joined: 14 Jul 2010
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PostPosted: 21:27 - 24 Apr 2012    Post subject: Reply with quote

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
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wilz1234
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Joined: 14 Jul 2010
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PostPosted: 21:29 - 24 Apr 2012    Post subject: Reply with quote

Tim.. wrote:
Nice work...but for me the seat unit doesnt fit the style of the rest of the bike

Have some Thumbs Up Karma though Wink


I think I must have a thing for modern looking bikes but I've loved the zxr ever since I got one xD
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CaNsA
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PostPosted: 21:36 - 24 Apr 2012    Post subject: Reply with quote

*pokes with stick*
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Gazza M
Crazy Courier



Joined: 19 Nov 2010
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PostPosted: 21:43 - 24 Apr 2012    Post subject: Reply with quote

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!
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wildmark13
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PostPosted: 22:56 - 25 Apr 2012    Post subject: great project Reply with quote

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! Smile
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Old Thread Alert!

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

wilz1234
Trackday Trickster



Joined: 14 Jul 2010
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PostPosted: 12:53 - 18 Dec 2013    Post subject: Reply with quote

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
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Billing
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PostPosted: 04:15 - 19 Dec 2013    Post subject: Reply with quote

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.
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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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