ZX7R track/road bike project

[Tristan.]

A few months ago I picked up a ZX7R, no MOT, but roughly road ready - leaking fork seals and needed new tyres but nothing obvious wrong. I had to take it apart to get it home though:
https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/87E6D99D.jpg
https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/E977C51D.jpg
I put it back together but didn't bother putting it on the road as I had plans.
A few weeks later I picked up another one in a worse state. Non running with no bodywork, though the engine turns over. Anyway they then got left in the garage/garden for ages. Now I've finally cleared out my 'workshop'/conservatory I'm going to start my project.

Aim is to have one road bike and one track bike, so all the cosmetically nicer bits go on the roadbike and all the more trick bits go on the trackbike.

First difficulty was getting the fuckers in the house. Scrappy went in with no major problems - I removed her brakes as they where seized on, the nicer one was a little more troublesome-
https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/51DB2751.jpg
stupid chubby ninja is too heavy to get over the step.

I decided to charge the battery, that bike does run, but even if it wouldn't I could still stick it in first, bridge the clutch switch and bump it over with the starter motor. After charging a spare battery I stuck it on and went to turn her on - for some reason the ignition barrel decided to stop working, so ten minutes struggling with that, greasing oiling etc I gave up and decided to just bridge the starter solenoid... a half hearted fart from the starter motor and nothing. Turns out my spare battery is fucked. There was nothing for it but to man up so I pumped up both tyres, had some weetabix and managed it after about 10 minutes nearly shitting myself.
https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/69DFDAC7.jpg
The dog is not happy with these new family members.

Now I had a bit more room I could put the steering lock on, which made the ignition work. Then I popped a working battery on the nicer one and got her running. Horrible clicky noise from the RHS of the engine though, I'm assuming these run auto CCTs, might look into a manual one. Didn't bother putting a battery on the other one, I'll drop the oil first and see if there's anything nasty in the sump.

So now the plan is to identify what parts I have available, and what bike they will work best on and get a list of what needs to be bought.

front to back I have
1 set of wheels with new bearings and fucked tyres
1 set of wheels with decent BT-014s
1 set of EBC pro-lite disks
1 set of cast iron disks
1 set of standard disks
2 sets of tokiko 6 pots
1 set of leaking forks, and the seals for them
1 set of non leaking forks
1 steering damper
1 nice standard tank
1 primed tank
1 standard, fairly scrappy fairings inc headlights vents etc
1 scorpion full system
1 arrow hi-level full system (which fouls the indicator)
1 working engine with a noisy CCT
2 engines in unknown condition
2 sets of carbs unknown condition
1 technoflex shock
2 standard shocks
2 sets of standard pegs
1 set of spacer plates
1 set of aftermarket adjustable rearsets
1 standard tail with pillion seat
1 fibreglass tail unit
2 half decent C&S fitted, with various sizes of rear sprocket.

So the main expense is going to be a fibreglass front fairing, then all the general service bits and bobs unless there's something majorly wrong with both non running blocks. Next stage was to start on a full service. I figured if I start by stripping down to check the valve clearances and grease the shock linkages thats pretty much the whole thing stripped down so I'll start there.

https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/F600177B.jpg
scrappy is actually much cleaner under the tank than the other one

https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/B3F7F31A.jpg
precision engineering employed to remove top yoke nut ( I did just turn the spanner, but it started lifting the bike on the stand

https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/F77098F6.jpg
bike archeology - so why at some point has this guy had to buy new carbs from a breakers

https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/80F8DE03.jpg
as they stand now. I've dislodged the carbs from the manifolds, but I can't remove them as they have heaters, so I'll have to drain the coolant before I can carry on.

Anyway thats where I got to before lunch, now I have to grab something to eat and do a bit of shopping. Should have another update this evening.

Oh and I'll quickly pimp my homemade workbench - £15 of discount timber and about £20 of threaded bar and coach screws and some free pallets
https://i35.photobucket.com/albums/d170/tristanthe/Snapbucket/219861D4.jpg

[moppy]

Nice, big fan of these bikes, will be watching with interest.

[Ollie1995]

+ Karma for getting it in a micra
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XR 125, DT125 LC, Greeves Scottish, RS200, XS400, GPX600r

Theory Passed - 18/7/13 MOD1 Booked - 24/9/13

[Bike Bunker]

massively impressed you got it in a micro..... view my thread on my zx7r project currently rebuilding 2 7r engines ready to fit to the bike

[Bike Bunker]

if your interested i have a racing muzzy engine available a big end bearing went so i am in the process of replacing it and will fit a full £180 oem gasket set and will be selling it for £500

[Tristan.]

[wilz1234]

Niice It's a familiar sight

I believe the bit on top is a valve that opens to let air from the intake into the exhaust port to get rid of unburnt fuel. It's all in the haynes book of lies
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RS50 - ZXR400 - ZXR 400 - ZX7R - Bandit 600 - NTV 650

[Bike Bunker]

wont be getting rid of the bike if i cannot get the money i want for it at the end though the maxton shock brembo m/c and carbon tarty bits will be going but if you watching the thread you'll know that

[evoboy]

Give us a shout if you need a hand with anything on this mate

Pretty clued up on them now

The ignition switch issue will be a badly soldered wire inside the ignition barrel. Youll have to take it off and re solder it on. I had to do this on mine, been fine since. They also tend to burn out the big connector block for the ignition under the tank, so take a look there.

As for the vent gubbins under the tank...

You can remove the valve sitting ontop of the rocker cover and just bridge to 2 pipes together. The other valve regulates pressure into the float bowls on the carbs. I would HIGHLY advise you keep that, as its a nightmare without.

Are they cast iron discs?! ( PFM?)
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Suzuki GT250 x7------- Fazer 600------CB250RS------Aprilia Rally 70----- Bandit 600

APT Motorcycles

[Tristan.]

[evoboy]

Try pushing the key forward or back in the barrel when turning the key.

Some ignition barrels wear funny from people having too many keys on the keyring.

The block connector is the one im talking about. Altho im not sure why it has a random spade connector on it!
____________________
Suzuki GT250 x7------- Fazer 600------CB250RS------Aprilia Rally 70----- Bandit 600

APT Motorcycles

[bacon]

[Bike Bunker]

what are you doing for gasket sets as there not many aftermarket ones available and non of them are under £160 from what ive found ?

[Tristan.]

[kat250]

Best thing you can do with those calipers is stick a set of 4 pots on. Seriously the 6 pots are rubbish.
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in the famous word of jimmy pop "would you F*ck me for blow"
In the words of banditshigh "would you blow me to f*ck"

[Tristan.]

[Turkish]

[bacon]

[Tristan.]

[bacon]

[suzukirider19...]

good work mate doing a very simlar project myself but a zx6r F3
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husky sm610

[moppy]

Really enjoying this thread, keep the updates coming

[bacon]

lol found the thread I made with the condition of my tokicos, I wish back then I had an ultrasonic cleaner, they would have prob come up cleaner than a toothbrush and brake cleaner managed!

https://www.bikechatforums.com/viewtopic.php?t=194978&highlight=tokico+caliper

[Red Devil]

Nice work mate, looking forward to how these turn out
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Thundersport Pre-National Sport 600 2014 #92
EMRA Roadstock 600 2013 - 3rd
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