My ZXR400 project

[James306]

Bought as my first big bike, and to use as the daily hack while I'm at uni as my 205 was crazily thirsty on petrol.

Bought her in September after I had passed my test, reasonable price considering her age and milage (62k km) and a few issues to boot!

Here's a couple of pics of the ol'girl!

https://i150.photobucket.com/albums/s92/jamieanderton1/270398_10151072458806261_358995494_n.jpg
https://i150.photobucket.com/albums/s92/jamieanderton1/548424_10151072458851261_1005896163_n.jpg

First problem was that the tank was loose and was knocking about when I went over any bumps, I was assured it was a missing bolt so thought it would be easier enough to sort. Upon checking I found that not only was the tank held in place by only one bolt, but the nearside bracket on the front had sheared clean off!

Top top all this off I managed to get a piece of 12mm long flint stuck in the rear tyre, which was nearing the limit anyway, but got to the bike one evening at college to find the tyre was flat....

Time to get a few things sorted on her! Luckily I hadn't yet sold the 125 so had transport for the week and managed to find a part work, almost new Dunlop sport qualifier II to replace the one on the back and keep the tyres matching!

Pulled the tank off with the intention of getting away with welding the bracket back on! Found that was a no go because the repair would have been far too close to the seam on the tank (Boom) so with advice from my welding tutor at college a plan was formed!

https://i150.photobucket.com/albums/s92/jamieanderton1/IMAG0373_zps372c07eb.jpg
Broken bracket

Couldn't weld onto the tank itself, but the remains of the bracket were still there, and a good 5-6mm away from the tank wall, so the plan was double skin the bracket!

I knocked up a pair of brackets to seat inside the originals using 3mm mild steel plate

https://i150.photobucket.com/albums/s92/jamieanderton1/IMAG0376_zps21ca4d99.jpg
Bending to shape

https://i150.photobucket.com/albums/s92/jamieanderton1/IMAG0379_zps540bff12.jpg
Profiled

https://i150.photobucket.com/albums/s92/jamieanderton1/IMAG0385_zpscb955005.jpg
Completed pair

After a week of venting the tank I bravely allowed my welding tutor to attack it with the MIG welder (I quite like my eyebrows....and hair...and skin.....)

https://i150.photobucket.com/albums/s92/jamieanderton1/IMAG0389_zps9e19e0a2.jpg
Bracket seam welded in place

Then after a few coats of matt black to stop it from rusting, but brackets were sorted and far stronger than factory standard!

https://i150.photobucket.com/albums/s92/jamieanderton1/IMAG0392_zpsbfa85a1d.jpg
Finished article

Popped the tank back on and she's solid as a rock

Since then all I have really done with her is a service, new dash bulbs and chain tension!

Still a few niggles, but all to be expected with an 18 Y/O bike! One being a slight knocking from the front on bumps but I have yet to locate where it's coming from... Nothing appears lose but I'm sure it will come to light eventually!

Oh, a quick snap of her in the new forest this evening, sun was out and I was home by 3:30, would have been rude not too!

https://i150.photobucket.com/albums/s92/jamieanderton1/841072_10151213881196261_1480224986_o_zps723fca0b.jpg
Got to love rush hour in the new forest

[Supermoto_Fan]

That's a lovely bike, always liked them, not keen on the stubby can though, think they look gash
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Yamaha MT-09 - Triple powerrrr

[thomp1983]

nice work with the tank bracket but all you needed to do was purge the tank and you could of welded straight to it. as for the can see if you can get a scorpion can and micron downpipes ala

https://i46.photobucket.com/albums/f109/thomp1983/20110719_002.jpg

chris