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MillaMeter's Mk2 Rebuild (Warning Lots Of Photos)

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MillaMeter
Nova Slayer



Joined: 24 Dec 2005
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PostPosted: 23:44 - 16 Nov 2009    Post subject: MillaMeter's Mk2 Rebuild (Warning Lots Of Photos) Reply with quote

Hi,

I started doing this rebuild last month but only just got round to posting it on BCF. It is plastered all over zxrworld's forum but thought I'd post it all here aswell. The bike i have owned since Nov 2007 It's a ZXR400 L2 with a ZX400 G 1988 engine currently producing 67bhp at the rear wheel. Engine is completely standard, dynojetted carbs, micron headers with custom end can.

I do apologize for the million images Embarassed

Here she is before I take her clothes off.

https://img269.imageshack.us/img269/4055/25732790.jpg

Clothes coming off now Shocked

https://img382.imageshack.us/img382/9323/15102009492.jpg

https://img42.imageshack.us/img42/6121/15102009491.jpg

https://img203.imageshack.us/img203/4527/15102009494.jpg

Arrrrg.... fecking bolts Evil or Very Mad

https://img42.imageshack.us/img42/2424/15102009495.jpg

https://img396.imageshack.us/img396/5164/15102009497.jpg

https://img131.imageshack.us/img131/1318/16102009504.jpg

https://img96.imageshack.us/img96/2373/16102009498.jpg

https://img240.imageshack.us/img240/5288/16102009499.jpg

https://img131.imageshack.us/img131/9440/16102009500.jpg

https://img507.imageshack.us/img507/3909/16102009501.jpg

https://img390.imageshack.us/img390/7946/16102009502.jpg

https://img210.imageshack.us/img210/1687/16102009503.jpg

https://img527.imageshack.us/img527/6191/16102009512.jpg

https://img169.imageshack.us/img169/7317/16102009505.jpg

https://img169.imageshack.us/img169/833/16102009506.jpg

https://img127.imageshack.us/img127/534/16102009510.jpg

https://img42.imageshack.us/img42/2784/16102009511.jpg

https://img67.imageshack.us/img67/4736/17102009514.jpg

https://img266.imageshack.us/img266/1091/17102009518.jpg

https://img25.imageshack.us/img25/7075/17102009519.jpg

https://img169.imageshack.us/img169/5816/17102009520.jpg

https://img200.imageshack.us/img200/7539/17102009521.jpg

https://img67.imageshack.us/img67/5053/17102009522.jpg

https://img210.imageshack.us/img210/4774/17102009523.jpg

https://img210.imageshack.us/img210/4821/17102009524.jpg

https://img266.imageshack.us/img266/3986/17102009525.jpg

https://img25.imageshack.us/img25/5808/17102009526.jpg


https://img132.imageshack.us/img132/9149/19102009537.jpg

https://img34.imageshack.us/img34/6373/19102009538.jpg

https://img15.imageshack.us/img15/7518/19102009539.jpg

https://img26.imageshack.us/img26/3628/19102009540.jpg

https://img132.imageshack.us/img132/204/19102009541.jpg

https://img8.imageshack.us/img8/9605/21102009548.jpg

At this point everything is ready for powdercoating.

Some parts arrive from Kawasaki Very Happy

https://img687.imageshack.us/img687/7215/03112009566.jpg

Back from the powdercoaters!

https://img4.imageshack.us/img4/5949/03112009567.jpg

https://img156.imageshack.us/img156/3598/03112009568.jpg

https://img94.imageshack.us/img94/6135/03112009569.jpg

Had to clear coat the frame for that little bit extra protection.

Here's my method of spraying a frame completely off the ground.

https://img689.imageshack.us/img689/9848/06112009570.jpg

https://img175.imageshack.us/img175/6361/06112009571.jpg

My idea of counter balancing the washing line ( ya mum will never know Wink )

https://img97.imageshack.us/img97/1299/06112009572.jpg

https://img257.imageshack.us/img257/6885/06112009595.jpg

https://img175.imageshack.us/img175/1724/06112009598.jpg

https://img39.imageshack.us/img39/2867/06112009606.jpg

Polished the bottom yoke.

https://img175.imageshack.us/img175/525/06112009610.jpg

I then got bored of waiting for bits to arrive so I decided to work on the engine and replaced the head gasket, cam chain and all 3 guides. I did run into quite a big problem, the inlet cam has very bad grooves on the 3rd cylinder lobes so now that's going in the biffa. All 8 inlet rockers have been munched at by the camshaft so they have to go in the biffa aswell.

Luckily a mate of mine has sorted me out with a new camshaft and 8 new rockers.

All images are in order I done the parts.

https://img109.imageshack.us/img109/2058/10112009638.jpg

https://img697.imageshack.us/img697/7021/10112009639.jpg

https://img252.imageshack.us/img252/3674/10112009641.jpg

https://img265.imageshack.us/img265/815/10112009642.jpg

https://img257.imageshack.us/img257/9960/10112009647.jpg

https://img5.imageshack.us/img5/8504/10112009648.jpg

https://img171.imageshack.us/img171/6536/10112009643.jpg

https://img204.imageshack.us/img204/3215/10112009644.jpg

https://img5.imageshack.us/img5/3963/10112009645.jpg

https://img5.imageshack.us/img5/2878/10112009646.jpg

https://img171.imageshack.us/img171/6897/10112009649.jpg

https://img5.imageshack.us/img5/3163/10112009650.jpg

https://img204.imageshack.us/img204/1913/10112009651.jpg

https://img213.imageshack.us/img213/8701/10112009652.jpg

https://img260.imageshack.us/img260/5476/10112009653.jpg

https://img257.imageshack.us/img257/8312/10112009654.jpg

Here's just 1 of 8 of the rocker arms. mmmmmmm grooooovey

https://img17.imageshack.us/img17/4724/dscf0287e.jpg

More progress on the frame and wheels. Haven't got a photo of the front wheel yet as it needs a set of discs. Rear wheel is fully put together and ready to roll. Frame has new race bearings, top and bottom yoke polished to a mirror and bolted up. New dust seals top and bottom, stainless bolts looking like chrome. New caliper hanger bearing and dust seals.

https://img109.imageshack.us/img109/4259/08112009622.jpg

https://img697.imageshack.us/img697/4127/08112009623.jpg

https://img697.imageshack.us/img697/7082/09112009629.jpg

https://img697.imageshack.us/img697/619/09112009633.jpg

https://img233.imageshack.us/img233/5176/09112009634.jpg

https://img265.imageshack.us/img265/92/09112009635.jpg

https://img266.imageshack.us/img266/4757/09112009637.jpg

https://img130.imageshack.us/img130/9924/16112009664.jpg

https://img94.imageshack.us/img94/8420/16112009667.jpg

https://img697.imageshack.us/img697/7441/16112009669.jpg

https://img109.imageshack.us/img109/8969/16112009673.jpg

This is the current state of the bike ATM.

Stay tuned

Regards

Rich


Last edited by MillaMeter on 04:41 - 21 Dec 2009; edited 1 time in total
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ms51ves3
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Joined: 07 Jun 2007
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PostPosted: 01:00 - 17 Nov 2009    Post subject: Reply with quote

Who is the wavy disc made by?

If it is made by a company called Kagizume be wary.

ms51ves3 wrote:
In the Feb 09 issue of Bike they tested one on a TZR250 and 'it lasted one 10-minute track session before warping'.


Nice project though.
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chris-red
Have you considered a TDM?



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PostPosted: 01:10 - 17 Nov 2009    Post subject: Reply with quote

ms51ves3 wrote:
Who is the wavy disc made by?

If it is made by a company called Kagizume be wary.

ms51ves3 wrote:
In the Feb 09 issue of Bike they tested one on a TZR250 and 'it lasted one 10-minute track session before warping'.


Nice project though.


I have a kagizume disc on the rear of my TDM didn't notice any difference over standard.
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MillaMeter
Nova Slayer



Joined: 24 Dec 2005
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PostPosted: 05:47 - 17 Nov 2009    Post subject: Reply with quote

Hi,

Yeah the disc is made by Kagizume but I've used these rear discs before and had no problems what so ever. To be very honest with ya there is no difference over standard... they just look cooler. The reason I got another new rear disc on the rear wheel now is because I was given it so thought why not... and fitted it. Still have the old 1 which has only done something stupid like 500 miles and is still straight as a die. Up for grabs if anyone is interested Razz

Regards

Rich
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alun111
World Chat Champion



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PostPosted: 10:27 - 17 Nov 2009    Post subject: Reply with quote

Very nice, you've done a brilliant job on the polishing! I'd replace that chewed up top yoke nut though.. and buy a nice 6 point socket for removing it in the future.
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Whosthedaddy
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PostPosted: 10:50 - 17 Nov 2009    Post subject: Reply with quote

Its is very satisfying putting a bike back together again after stripping and cleaning it. Looking good so far, but c'mon white wheels? They have to be green!
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MillaMeter
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PostPosted: 22:09 - 18 Nov 2009    Post subject: Reply with quote

Hi,

Thought I'd have a go at painting the engine today, it looks tacky at the moment but once I've polished all the bolts and replaced the rover cover gasket it'll look good as new again. I'll be swapping the crappy water hoses for samco sport silicone ones for better water flow.

https://img196.imageshack.us/img196/2517/18112009679.jpg

https://img196.imageshack.us/img196/1003/18112009680.jpg

https://img691.imageshack.us/img691/8452/18112009681.jpg

https://img697.imageshack.us/img697/6379/18112009678.jpg

Regards

Rich
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MillaMeter
Nova Slayer



Joined: 24 Dec 2005
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PostPosted: 04:19 - 21 Dec 2009    Post subject: Reply with quote

Hi,

This was done a while ago, just got so busy didn't have time to post it all.

Finally got the front discs on and bolted all up with shiny stainless disc bolts. I found some new bearings for the spension pivot arm, £40 delivered for 5 bearings only problem is now is that the collers that go into the bearings are shagged. 1 of them has bearing marks where the bearings seized up and just put dents in it. Looks like another phone call to Kawasaki in the morning.

https://img690.imageshack.us/img690/782/26112009691.jpg

https://img36.imageshack.us/img36/766/26112009692.jpg

https://img28.imageshack.us/img28/8554/26112009694.jpg

https://img517.imageshack.us/img517/351/26112009688.jpg

https://img28.imageshack.us/img28/7901/26112009690d.jpg

top of forks have been polished, stanchions cleaned up, axle pinch bolts polished and the front axle nut polished. I finally found a swingarm which I picked up last last weekend and just picked it up from the powdercoaters which I must say looks awesome.

There are some before and after shots.

https://img413.imageshack.us/img413/1159/30112009719.jpg

https://img37.imageshack.us/img37/6274/30112009720.jpg

https://img687.imageshack.us/img687/7513/30112009721.jpg

Before Clean
https://img413.imageshack.us/img413/3134/30112009713.jpg

After Clean
https://img687.imageshack.us/img687/5168/30112009714.jpg

https://img403.imageshack.us/img403/8996/30112009715.jpg

https://img413.imageshack.us/img413/3239/30112009716.jpg

https://img413.imageshack.us/img413/5160/30112009717.jpg

Both before and after in the same shot, right 1 is polished.
https://img101.imageshack.us/img101/6084/30112009718.jpg

Swingarm looking gravy!
https://img121.imageshack.us/img121/6988/30112009722.jpg

https://img687.imageshack.us/img687/6027/30112009724.jpg

https://img199.imageshack.us/img199/4440/30112009725.jpg

Next on the list is to paint the bottom of the fork legs silver, replace the swingarm bearings ( powdercoaters shot blasted them :smt009 ) polish some more bits and bobs, get hold of a new rear shock and get a rolling frame at least.

~Week later:

Here's some more progress on the rear end. Swingarm has been lacquered and looking rather gravy, brand new chain runner, lots of polished bolts blah blah blah, new swingarm bearings, shock stripped and cleaned up very very well. Getting the spring powdercoated white or black haven't decided yet but which either way it's gona look nice. Sorry to say but these picture just don't do it justice. My camera phone is shite so I do apologise for the poor images.

https://img705.imageshack.us/img705/7356/07122009739.jpg

https://img189.imageshack.us/img189/1674/07122009740.jpg

https://img18.imageshack.us/img18/9708/07122009741.jpg

https://img24.imageshack.us/img24/5727/07122009748s.jpg

https://img697.imageshack.us/img697/4600/07122009749.jpg

https://img704.imageshack.us/img704/4449/07122009751.jpg

https://img687.imageshack.us/img687/993/07122009752.jpg

https://img18.imageshack.us/img18/5615/07122009759.jpg

https://img687.imageshack.us/img687/5706/07122009761.jpg

Tiny update as money is tight (what do you expect at this time of year) anyway. Been waiting a week for some powdercoating bits to come back which came back today. Think I'll let the 2 pictures do the talking shall I? I took 2 pictures under different lighting cause it was taken under crap light and didn't know which 1 looked the most effective.

Before:
https://photos-h.ak.fbcdn.net/hphotos-ak-snc3/hs028.snc3/11555_359136560607_514330607_10085833_1326433_n.jpg

https://photos-e.ak.fbcdn.net/hphotos-ak-snc3/hs008.snc3/11555_359136570607_514330607_10085834_7981022_n.jpg

After:
https://img32.imageshack.us/img32/5656/15122009778.jpg

https://img693.imageshack.us/img693/3361/15122009779.jpg

Regards

Rich
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Gazdaman
I did a trackday!!!



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PostPosted: 10:03 - 21 Dec 2009    Post subject: Reply with quote

Great work, can't wait to see more!

Gaz
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alun111
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PostPosted: 11:51 - 21 Dec 2009    Post subject: Reply with quote

+1

Awesome!
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Jamie S
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PostPosted: 21:35 - 24 Dec 2009    Post subject: Reply with quote

What are you using for polishing up the ally bits ?
Jamie.
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yvaiwhy
Borekit Bruiser



Joined: 26 Feb 2009
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PostPosted: 19:51 - 26 Dec 2009    Post subject: Reply with quote

luv the bike and thnx for updating as much as you could Smile looking forward to see more Very Happy
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MillaMeter
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Joined: 24 Dec 2005
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PostPosted: 18:51 - 17 Jan 2010    Post subject: Reply with quote

Hi,

Sorry for the late update but I've been screwing around getting my new garage organized and lighting hooked up. I would show you guys alot more then these few images but that would be spoiling it a lil too quickly. I'll show a full pic of the bike when I get the new wheel spacers from Japan ( Cradley's had non in stock so that's a 6-8 week wait.

I got this funky clear tail light from M&P the other week, will be getting the clear indicator lenses to match aswell.

https://img148.imageshack.us/img148/7844/29122009807t.jpg

https://img39.imageshack.us/img39/2293/24122009801.jpg

https://img39.imageshack.us/img39/6398/29122009812.jpg

https://img63.imageshack.us/img63/6163/24122009800.jpg

https://img691.imageshack.us/img691/5273/24122009805.jpg

https://img8.imageshack.us/img8/674/24122009804.jpg

Hope you like it so far, cause I dribble everytime I see her Shocked

Regards

Rich
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Old Thread Alert!

There is a gap of 196 days between these two posts...

MillaMeter
Nova Slayer



Joined: 24 Dec 2005
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PostPosted: 11:39 - 02 Aug 2010    Post subject: Reply with quote

Hi,

Did anyone want to see the outcome of this project?

Regards

Rich
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jack_zxr400
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PostPosted: 11:50 - 02 Aug 2010    Post subject: Reply with quote

I really do lol

I love ZXR 400''s.. miss mine to bits Sad
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Tim..
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PostPosted: 11:50 - 02 Aug 2010    Post subject: Reply with quote

MillaMeter wrote:
Hi,

Did anyone want to see the outcome of this project?

Regards

Rich


Yep, with even more pics
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CHR15
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PostPosted: 14:13 - 02 Aug 2010    Post subject: Reply with quote

Quote:
Hi,

Did anyone want to see the outcome of this project?

Regards

Rich


er... YES!!!

'pimptastic' doesnt do it justice.
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rac3r
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PostPosted: 14:14 - 02 Aug 2010    Post subject: Reply with quote

Yes Please!

I was reading it then got to the bottom with no ending Crying or Very sad
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MillaMeter
Nova Slayer



Joined: 24 Dec 2005
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PostPosted: 19:46 - 02 Aug 2010    Post subject: Reply with quote

Hi,

Ok then here goes...

After all, my wheel spacers arrived.

Can't believe how well the side stand turnt out!

I also finished polishing up the exhaust hanger and fitting the other brand spankin new rear panel Very Happy

https://img193.imageshack.us/img193/4942/20012010878.jpg

https://img192.imageshack.us/img192/3650/20012010877.jpg

https://img638.imageshack.us/img638/2745/20012010876.jpg

https://img192.imageshack.us/img192/5829/20012010875.jpg

https://img517.imageshack.us/img517/6485/20012010873.jpg

https://img192.imageshack.us/img192/4760/20012010872.jpg

https://img96.imageshack.us/img96/6475/20012010871.jpg

https://img517.imageshack.us/img517/5825/20012010866.jpg

After all the stupid weather (snow), I decided to knuckle down and get dirty (quite literally with my polishing kit)
I got a lush L9 radiator all freshend up with a powdercoated grill, polished fan switch, and stainless bolts. Also got a set of 4 clear indicator lenses which I must say look very cool. Clutch lever polished like chrome, exhaust strap arrived and modded it abit by sticking green tape behind the laser cut to make it unique Smile

https://img402.imageshack.us/img402/5548/06022010938.jpg

https://img136.imageshack.us/img136/8538/06022010936.jpg

https://img685.imageshack.us/img685/7201/06022010934.jpg

https://img148.imageshack.us/img148/4932/06022010928.jpg

https://img684.imageshack.us/img684/1898/08022010966.jpg

https://img514.imageshack.us/img514/6127/08022010965.jpg

https://img402.imageshack.us/img402/3629/08022010964.jpg

https://img707.imageshack.us/img707/861/08022010963.jpg

https://img171.imageshack.us/img171/999/08022010962.jpg

https://img708.imageshack.us/img708/67/08022010961.jpg

https://img706.imageshack.us/img706/3180/08022010960.jpg

https://img208.imageshack.us/img208/9454/08022010959.jpg

https://img31.imageshack.us/img31/5391/08022010958.jpg

https://img99.imageshack.us/img99/8002/08022010956.jpg

https://img17.imageshack.us/img17/8127/08022010955.jpg

https://img695.imageshack.us/img695/7126/08022010954.jpg

https://img40.imageshack.us/img40/94/08022010952.jpg

https://img17.imageshack.us/img17/2041/08022010947.jpg

https://img205.imageshack.us/img205/6920/08022010946.jpg

https://img341.imageshack.us/img341/5277/06022010940.jpg

https://img641.imageshack.us/img641/5681/06022010939.jpg

Well, I am proud to say I finished polishing up the zorst and topped her up with bike fluids and she growled into life!!!!

She purrrrrs like a kitten and is sooooo smooth compared to what she sounded like before. I decided to rip her out the garage in the sunshine and took a few piccies. Amazingly she has NO leaks at all! A quick carb balance and plug clean and shes sound!

https://img100.imageshack.us/img100/2789/160320101063.jpg

https://img59.imageshack.us/img59/9148/160320101062.jpg

https://img638.imageshack.us/img638/911/160320101061.jpg

https://img213.imageshack.us/img213/3829/160320101060.jpg

https://img260.imageshack.us/img260/5905/160320101059.jpg

https://img682.imageshack.us/img682/5573/160320101058.jpg

https://img683.imageshack.us/img683/9048/160320101057.jpg

https://img692.imageshack.us/img692/3335/160320101056.jpg

https://img121.imageshack.us/img121/7233/160320101055.jpg

I have now got round to overhauling the gen cover, she also has a chain and sprocket set on now. I have blatted it up and down the road a few times and doesn't seem to pull as she did 6 months ago. (prob due to still having 6 month old fuel in the tank) I'll get it sorted on the dyno aswell, will be interesteing to see what shes kicking back there.

https://img301.imageshack.us/img301/1779/080420101131.jpg

https://img688.imageshack.us/img688/8228/080420101129.jpg

https://img338.imageshack.us/img338/2807/080420101130.jpg

https://img217.imageshack.us/img217/3136/010420101112.jpg

And finally this is how she currently stands untill I can find a nice enough lower panel.

https://img839.imageshack.us/img839/7192/280520101163.jpg

https://img341.imageshack.us/img341/2779/280520101164.jpg

https://img256.imageshack.us/img256/1390/280520101165.jpg

https://img805.imageshack.us/img805/5676/280520101166.jpg

https://img812.imageshack.us/img812/8206/280520101167.jpg

Regards

Rich
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rac3r
World Chat Champion



Joined: 04 Sep 2007
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PostPosted: 19:56 - 02 Aug 2010    Post subject: Reply with quote

Very nice, good job!

Not keen on the rim tape myself but the brake lines look awesome. Cool bike Thumbs Up
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locked
Could Be A Chat Bot



Joined: 22 Oct 2009
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PostPosted: 20:15 - 02 Aug 2010    Post subject: Reply with quote

looks fantastic! great job Thumbs Up
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ms51ves3
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Joined: 07 Jun 2007
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PostPosted: 20:53 - 02 Aug 2010    Post subject: Reply with quote

Excellent work Thumbs Up Karma
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Carl_steveo
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Joined: 23 Jun 2008
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PostPosted: 21:20 - 02 Aug 2010    Post subject: Reply with quote

Oooo shiny shit I likes it.
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