Kawasaki ZZ6R - a mixture of many machines

[SteveZZR]

Hello all,

This machine has been through hell and back.
I dare say It would've been a Category B write off if those 'necessary' money stealing arsehole "insurance companies" had been able to get near it as the frame and engine both took a hit in a crash in October '12. I hit diesel on a straight road, which also happened to be a hill. Long story short, a tank slapper I tried to hold on to turned into a rear wheel flinging out from under me and the bike went several hundred meters in a straight line and destroyed the engine and scuffed up the frame.
[IMG]
https://i1188.photobucket.com/albums/z413/SteveZZR/CrashedZZR/DSC00529.jpg[/IMG]
https://i1188.photobucket.com/albums/z413/SteveZZR/CrashedZZR/DSC00533.jpg

First look suggests just the engine casings but a closer look and you'll see that the clutch basket took a whack and the crank cases took a hit.

Luckily I got a complete new engine form XXX bike breakers in Bradford (decent set of blokes there, would recommend them - especially their "cash price" on items )

Rebuilt the bike like this:
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/bike.jpg

Using parts I had laying around and parts from a ZZR 400 (same as ZZR 600 other than carbs, top end, and exhaust headers).

Used this to get around until the absolute legend, and my best friend, Slam sold me his old CG 125
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000160_zps8107e459.jpg

Which I then used as my transport, whilst I developed some custom bodgery to fit a ZX6R J (00-02) fairing to my ye olde ZZR.
After loads of pissing about and such I ended up with this

https://i1188.photobucket.com/albums/z413/SteveZZR/ZZ6Rg_zpsc53b05a2.jpg


Quite pleased so far, really could do with a better paint job on the front fairings as I used Tesco Value sand paper and spend all of 30 minutes spraying it. Didn't bother with the tank, just put a blue Bagster on it.



And also, for future reference: the 1990 CG 125 is a fucking awesome bike

https://youtu.be/amSv66yOTno

[SteveZZR]

Forgot to add

all mods from stock:

ZX6R J fairing, headlight and mirrors
Bi-Xenon Projector HID fittings in the J headlight
Koso DB01plus Digital instruments / Dash
ZZR 1200 rear shock (overall better unit + remote preload)
CBR FireBlade front calipers
ZX9R C Front Master Cylinder
HEL Braided lines front + rear
CBR1000F clip ons + forks raised 10mm in yokes

Coming soon:
ZX6R F forks + wheel (just need to do oil + seals on forks)
Generic digital gear indicator off eBay

Next:
ZX6R J swingarm + wheel to allow use of 180 rear tyre

[mysterious_rider]

Nice man, looks pretty good! I've crashed my zzr a few times with not too much damage. They are quite sturdy.
____________________
KAWASAKIIIII

[SteveZZR]

[Tiff]

Yup, strong bikes! I did this to a Polo with mine, and broke the clutch lever.. rode it home, from Germany- rode arrow straight.

https://i3.photobucket.com/albums/y73/tiffx19/29072012111.jpg
____________________
1996 Kawasaki GPZ1100s,1996 VFR750,1980 BMW R80,1982 Kwak Z250B,1992 ZZR1100C,1996 BMW K1100LT,1994 Kwak ZZR600E,1993 BMW R1100RS,1992 ZZR 600D,1988 BMW K100LT,1998 Aprilia Pegaso 650,1994 Suzuki RF900,1991 Yamaha XJ600, 1988 Honda Dominator,1992 Kwak KMX125,1987 Yamaha RD50MX,1984 Honda MBX50.1984 Honda Superdream 125

[SteveZZR]

Some idiot hairdresser mowed me down on mine on one occaision

bike had fairing damage and little else

the Fiat 500 had a full on mashed in front end

[SteveZZR]

Came across these stashed in my garage today
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/ZX10forks_zps303ef13c.jpg

ZX10R USD forks.

Bought them a while back and stashed them away.

Test fitted on my spare frame today (should've gotten a pic - D'oh!) and they seem to fit but the stem is about 1/2 inch shorter than it needs to be - My 'test fit' involved skipping the C-spanner nuts and only just getting 3 turns on the top yoke nut. I'm fairly sure the ZZR 1400 stem will be long enough and they have the same size forks, spacing, and rake/trail/etc as far as I can tell. Going to borrow a friends ZZR 14 yokes and see if it'll work!
Measured it and the spindle hole is same size as the ZX6R J model wheel so with a custom spacer I can use a £90 wheel instead of a £300 wheel. With a little more lathe work I can use a £45 ZX6R F wheel by removing the speedo drive and changing the bearings.
The outside option is an ER6 front wheel which is a 120/70-17 like the ZX10R wheel and is the fancy Kawi multispoke pattern but eBays for around £100 or so.

ZX6R F wheel is a noticeably lighter than the ZZR wheel when you lift one, then the other so should be a nice reduction in rotating mass etc (I mean seriously, if running a 520 chain instead of 530 apparently makes a mega difference a lighter wheel must make a HUGE difference?)

Also got a ZX6R J swingarm to test fit on my spare frame and haven't yet decided on a rear wheel; if I end up with an early 6R wheel up front it'll be a G or J, if I go ER6 front wheel I'll cough up for an 05+ 636 rear wheel to match.


I did consider an overbore and using F model pistons and maybe some head work (youtube how to's and a spare top end I have from a damaged motor) but decided I can't be arsed at the moment.

[SteveZZR]

Wow, long time since I remembered to post here!

Pictures, Pictures and Pictures.

Had some machine work done, made the stock ZZR stem fit the ZX10R yokes, along with a ZX6R F wheel which has been machined out to take 47mm OD bearings (because I could get that done for £20 with spacers too, the wheel was £30, and Powder Coating was £30 making the total £80, compared to £90+ for a J wheel or newer)
Collars to go above and below the top yoke to reduce the size accordingly
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000769_zps0a490ce7.jpg

Top one fitted
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000770_zpsee4e5508.jpg

Bottom without collar
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000771_zpsfda6e579.jpg

Bottom with collar
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000772_zpsbee4ca23.jpg

Stem set in with bush
https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000773_zps70c0dddc.jpg

Forks fitted to the spare rolling chassis, came from a ZZR 400 N I bought for £150 and sold / used parts off. Well into profit on that purchase now - the rolling chassis and some other bits I've got were basically free in the end.

https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000775_zpsa837481d.jpg

https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000776_zps1d590ac3.jpg


https://i1188.photobucket.com/albums/z413/SteveZZR/ZZR%20600%20-%20ZX6J%20front%20end/WP_000778_zps2c148d74.jpg


Didn't have a spindle at the point that these pics were taken, hence the big screwdriver for test fitting.


All spaced up. Wheel sat nice and centrally in the yokes and everything now.
https://i1188.photobucket.com/albums/z413/SteveZZR/ZX10R%20fork%20swap/temporary_zps5a559c30.jpg

Chris has done a factory quality job of spacers / seals / etc.

Just need a bit of time to clean the calipers and fit new pads. Then I just need to hope that new pads will clear the discs - if that's the case then the pistons will automatically match up (outer one will stick out 2mm more to take up the slack) and all will be well.

Failing that I'll get some full-face spacers made to take up the 2mm.

Thought I'd just tag this on here!
The bike isn't even finished and I've had it in a Magazine!!!
Practical Sportsbike printed my email and a picture
https://i1188.photobucket.com/albums/z413/SteveZZR/temporary_zps531ae4e2.jpg

[mysterious_rider]

It's interesting, but do yourself a favour and ditch the zzr plastics. They are so fugly. If you are going to overhaul it fit a different tail piece!
____________________
KAWASAKIIIII