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Maintenance & Repair => Projects => Topic started by: Bullet on July 15, 2013, 04:43:54 PM

Title: Ive Bought another ZXR.....Update page 4
Post by: Bullet on July 15, 2013, 04:43:54 PM
Ive not been here for ages! but thought as I've just re-regitered i should post something......

so here it is, I've just bought this off my friend for £300

(http://i47.photobucket.com/albums/f185/lsjbagpuss/pinkwarriorninja.jpg)

needs some love and attention, but was too cheap to refuse, so this is to be a 'fix it cheap and ride it' project (as soon as i collect it that is!) things I know it needs are:
carbs stripping and cleaning
fuel tank draining and fresh fuel
fork seals
headstock bearings
rocker arm bearings
cush drive
MOT!

Things it could benefit from:
A wash!
new spark plugs
valve shims checking
fuel tank respray (stored upside down, fuel leaked and blistered off paint)
Title: Re: Ive Bought another ZXR.....
Post by: Green_Ninja on July 15, 2013, 04:50:10 PM
 :azn:  nice
Title: Re: Ive Bought another ZXR.....
Post by: greenmeeny on July 15, 2013, 06:39:53 PM
OOOO...is it raspberry!?!
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on July 15, 2013, 07:28:58 PM
Well I always mocked him for it looking pink in bright sunlight, so I cant really claim any different now I suppose!
Title: Re: Ive Bought another ZXR.....
Post by: Nib on July 19, 2013, 06:57:45 PM
J2 same as mine, lovely looking bike and a steal at that price. We talked many moons ago when I first bought mine, I asked you bout the zx10r shock conversion.
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on July 21, 2013, 01:56:26 PM
Quote from: Nib on July 19, 2013, 06:57:45 PM
J2 same as mine, lovely looking bike and a steal at that price. We talked many moons ago when I first bought mine, I asked you bout the zx10r shock conversion.

Exactly what I thought couldn't say no at that price, its a bit of a state at the moment and needs alot of love but they're great bikes I think (might be biased Ive had 5 now!) YepI remember talking about the 10r shock did you fit one in the end? This one already has one in it too as I fitted it for him about 5 years ago :)
Title: Re: Ive Bought another ZXR.....
Post by: Stuno1 on July 21, 2013, 03:49:25 PM
Looks sweet matey.
Title: Re: Ive Bought another ZXR.....
Post by: Nib on July 21, 2013, 07:20:21 PM
Yes mate, I found a 50 mile young zx10 shock for £40. Fitted it and then rode to Valencia and back in a week, no complaints and a much nicer ride.
I bought my zxr again this year after letting her go 4 years ago. Took alot of searching but I'll never let her go again.
Title: Re: Ive Bought another ZXR.....
Post by: zxrob on August 01, 2013, 10:32:09 AM
Dont you just love the old zxr's

Here's my K1, bought as a project, rather tatty and in need of some tlc, stripped her down to the bones, rebuilt as a trackbike, ohlins rear shock, re-chromed forks, 4-2-1 full akra, gsxr calipers and a whole lot of time and effort, repainted it myself

(http://p1.bikepics.com/2013/07/24/bikepics-2580370-800.jpg)

Rob
Title: Re: Ive Bought another ZXR.....
Post by: Green_Ninja on August 01, 2013, 11:10:47 AM
Quote from: zxrob on August 01, 2013, 10:32:09 AM
Dont you just love the old zxr's

Here's my K1, bought as a project, rather tatty and in need of some tlc, stripped her down to the bones, rebuilt as a trackbike, ohlins rear shock, re-chromed forks, 4-2-1 full akra, gsxr calipers and a whole lot of time and effort, repainted it myself

(http://p1.bikepics.com/2013/07/24/bikepics-2580370-800.jpg)

Rob

Lovely  :azn:
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on August 01, 2013, 12:27:41 PM
Quote from: zxrob on August 01, 2013, 10:32:09 AM
Dont you just love the old zxr's

Here's my K1, bought as a project, rather tatty and in need of some tlc, stripped her down to the bones, rebuilt as a trackbike, ohlins rear shock, re-chromed forks, 4-2-1 full akra, gsxr calipers and a whole lot of time and effort, repainted it myself

Rob

that is rather tasty  :cool: always loved the kawasaki france colours on these.  I rebuilt a K model once too (build thread here for anyone whos interested http://archive.mcnninjas.com/index.php?topic=26980.0 ) wish i never sold it now, mine didnt look as nice as that one though! Those extra 20 - 25 bhp make a big differance over the J dont they :)
Title: Re: Ive Bought another ZXR.....
Post by: zxrob on August 01, 2013, 01:08:35 PM
Quote from: Bullet on August 01, 2013, 12:27:41 PM
that is rather tasty  :cool: always loved the kawasaki france colours on these.  I rebuilt a K model once too (build thread here for anyone whos interested http://archive.mcnninjas.com/index.php?topic=26980.0 ) wish i never sold it now, mine didnt look as nice as that one though! Those extra 20 - 25 bhp make a big differance over the J dont they :)

Yeh, always liked the kwak france scheme

Mine is dynoed at 114 at the rear wheel and is so much fun to ride, engine is standard, yeh you can add a lot of factory/kit stuff to them but I just like it as is is with big heavy flatslides snorting at you :)

Rob
Title: Re: Ive Bought another ZXR.....
Post by: Gilby104 on August 01, 2013, 03:18:57 PM
What's that bar going to the back wheel? (not the swing arm!)
Title: Re: Ive Bought another ZXR.....
Post by: greenmeeny on August 01, 2013, 03:30:54 PM
Stops the rear brake going round and round when used. ;)
Title: Re: Ive Bought another ZXR.....
Post by: Nib on August 01, 2013, 10:48:02 PM
Any more pics of your zxr Rob? Looks beautiful.
Title: Re: Ive Bought another ZXR.....
Post by: Gilby104 on August 02, 2013, 10:02:25 AM
Quote from: greenmeeny on August 01, 2013, 03:30:54 PM
Stops the rear brake going round and round when used. ;)

Is that true?
Title: Re: Ive Bought another ZXR.....
Post by: zxrob on August 02, 2013, 10:30:47 AM
Quote from: Nib on August 01, 2013, 10:48:02 PM
Any more pics of your zxr Rob? Looks beautiful.

Yes I have some more

I will put a new thread up showing the rebuild when I get time

Only just realised, the above pic is with my shitty baffled can and not the akra

Rob
Title: Re: Ive Bought another ZXR.....
Post by: Nat on August 02, 2013, 11:03:44 AM
That's so pretty - love the colour!
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on August 02, 2013, 03:13:45 PM
Quote from: Gilby104 on August 02, 2013, 10:02:25 AM
Quote from: greenmeeny on August 01, 2013, 03:30:54 PM
Stops the rear brake going round and round when used. ;)

Is that true?

yes, he's not winding you up   ;)   its called a torsion arm, its what they used before they thought of putting a slot in the back of the swingarm to hold the caliper hanger in place on newer bikes.....
Title: Re: Ive Bought another ZXR.....
Post by: Nat on August 02, 2013, 04:14:01 PM
Quote from: Bullet on August 02, 2013, 03:13:45 PM
yes, he's not winding you up   ;)   its called a torsion arm, its what they used before they thought of putting a slot in the back of the swingarm to hold the caliper hanger in place on newer bikes.....

I thought they just put it there to make putting the wheel back in a pain in the ar3e!
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on August 02, 2013, 04:25:32 PM
Quote from: Nat on August 02, 2013, 04:14:01 PM
I thought they just put it there to make putting the wheel back in a pain in the ar3e!

that too!
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on October 09, 2013, 10:03:22 AM
Well its been a while since I actually made the deal, but I picked the bike up on saturday and it actually fired up after only about 15 seconds  :) bought a bunch of bits for it the first of which showed up today (zx7r rocker & dog bones) got a new cush drive in the post I have the fork seals and head bearings already though i do need to buy/make a seal driver and does anyone know of an easy way to get the existing head bearings off the lower yoke besides take them to a garage, because Im not paying £200 for a headstock bearing puller!
Title: Re: Ive Bought another ZXR.....
Post by: zxrob on October 14, 2013, 04:50:30 PM
Quote from: Bullet on October 09, 2013, 10:03:22 AM
does anyone know of an easy way to get the existing head bearings off the lower yoke besides take them to a garage, because Im not paying £200 for a headstock bearing puller!

Nick them very carefully with a small grinder, then, a quick few taps with a hammer will get them off

Rob
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on October 31, 2013, 10:34:06 AM
Well the project has progressed a bit, tackled the fork seals without any of the special tools required...

(http://i47.photobucket.com/albums/f185/lsjbagpuss/Pink%20Ninja/strippedfork.jpg)

(http://i47.photobucket.com/albums/f185/lsjbagpuss/Pink%20Ninja/finished.jpg)

spot the homemade tools, theres 2 of them in this photo.

easier than i thought it would be, but could have done with some extra hands to compress the spring!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/Pink%20Ninja/newbearing.jpg)

new bearing (that I already had spare from my old bike) installed onto new lower yoke (that I also already had!) again no special tool needed for this job either, metalworking vice and a hammer did the job perfectly well.

got a replacement rocker arm and dog bones off a zx7r for a bargain price so after a strip and regrease the only other bit i need to mot it is a new cush drive, and thats in the post :)
Title: Re: Ive Bought another ZXR.....
Post by: clipper on October 31, 2013, 12:46:40 PM
Quote from: Bullet on October 31, 2013, 10:34:06 AM

spot the homemade tools, theres 2 of them in this photo.


I'm guessing fork oil gauge (top of plastic spray bottle) and head bearing drift (big round metal tube)

:cool:
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on October 31, 2013, 01:20:35 PM
50% right  ;) spray bottle top is indeed an oil level tool! I did the head bearings using a metalworking vice and a hammer.

The other home made tool was this

(http://i47.photobucket.com/albums/f185/lsjbagpuss/Pink%20Ninja/homemadetool.jpg)

3 layers of cardboard tube sliced down the side so I can clip them around the fork leg and use them as a seal driver, some questionable types seemed to think it was for inserting gerbils somewhere the dirty sods!
Title: Re: Ive Bought another ZXR.....
Post by: clipper on November 01, 2013, 12:39:21 PM
Quote from: Bullet on October 31, 2013, 01:20:35 PM
50% right  ;) spray bottle top is indeed an oil level tool! I did the head bearings using a metalworking vice and a hammer.

What do I win?   :tongue:

Quote from: Bullet on October 31, 2013, 01:20:35 PM
The other home made tool was 3 layers of cardboard tube sliced down the side so I can clip them around the fork leg and use them as a seal driver

For the same job I used some Wickes downpipe and wall clamp which was an amazing fork seal driver. I have since bought the official Kawasaki service tool but my bodged version works just as well and better than braying bloody hell out any seal with a screwdriver!
:laugh:
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on November 02, 2013, 02:34:35 PM
Quote from: clipper on November 01, 2013, 12:39:21 PM

What do I win?   :tongue:


The respect of your fellow ninjas  :tongue:


Got the replacement cush drive in the post today, but found a few more jobs to do before its mot, need turn the brake lines round (theyve been put on upside down for some reason!) and it needs new spark plugs and fresh fuel, as it will start but missfires a bit and cuts out when trying to rev.... pretty sure new plugs will cure it as a remember my old one did the same thing when it had scabby spark plugs and it also used to eat them in about 4000 miles....
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on January 25, 2014, 06:11:23 PM
Been a while since any updates, but its progressed alot in the last couple of weekends, rebuilt forks are on, new head bearings in, brakes stripped and rebuilt and fitted, rear suspension linkages replaced with newly rebuilt ones, carbs stripped cleaned and back on, infact the only thing left to do to have it ready for an mot is a cush drive, as i bought the wrong one on ebay apparently and it doesnt fit! I think ive got a zx7r one?!
Title: Re: Ive Bought another ZXR.....
Post by: Nib on January 25, 2014, 06:47:13 PM
We need pictures!
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on January 27, 2014, 03:08:08 PM
I didnt actually take that many pictures this time round, but heres a few, sorry theyre not very good, or very exciting!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/482525_10153698110845212_863005425_n.jpg)

this is my friends parking spot that he's kindly let me dump the bike on for a while, bit of a step down from my own workshop but it has done the job! rebuilt front end going on, including rebuilt forks, brakes, new yokes and bearings, and re routing all the wiring (was in the wrong place) and respraying all the brackets for clocks/lights/fairing e.t.c

(http://i47.photobucket.com/albums/f185/lsjbagpuss/1604902_10153715996130212_1902106716_n.jpg)

makeshift workshop for rebuilding the carbs, it was actually quite comfy sat there with a movie on to do a spot of motorcycle maintenance!

This was a bit of a cock up ebay purchase, looked black in the picture! blue screen is going to look completely wrong on the bike, considering painting the inside surface black....
(http://i47.photobucket.com/albums/f185/lsjbagpuss/1510984_10153602437215212_200284696_n.jpg)
Title: Re: Ive Bought another ZXR.....
Post by: Nat on January 27, 2014, 05:24:25 PM
Love that red colour!
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on January 28, 2014, 09:50:44 AM
Quote from: Nat on January 27, 2014, 05:24:25 PM
Love that red colour!
The colour does look really good in that pic, but sometimes it does look very pink! and sadly the tank has suffered from a bad fuel spillage and paint blistering in the past, one side fairing is badly cracked and patched from the back, and the nose cone has scuffs and part missing where it joins the side, so im not sure weather to touch it up in places and leave it, or just respray the thing!, lazyness will probably cause me to just leave it, but I do have an Alloy tank and oe single seat tail from my old K model one I could put on it if I resprayed it!
Title: Re: Ive Bought another ZXR.....
Post by: Nib on February 01, 2014, 05:50:07 PM
Dont use the single seat, it'll look rubbish. Sell it to me really cheap instead!
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on February 04, 2014, 09:37:28 AM
theres one on ebay right now, not oe though i dont think, and its the wrong colour. Too far for me to collect or id have bought it as a spare! are you anywhere near herts?

http://www.ebay.co.uk/itm/Kawasaki-ZXR-750-J1-J2-Seat-Unit-/201030526601?pt=UK_Motorcycle_Parts_13&hash=item2ece5a6689
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on February 08, 2014, 01:49:22 PM
now has an MOT, only need tax now  :moto:  then theres a whole lot more jobs to do to make it not shit aswell as legal!
Title: Re: Ive Bought another ZXR.....
Post by: Nib on February 14, 2014, 04:29:51 PM
I was watching that seat but sadly he wouldnt post and im a candy red j2 also.
Title: Re: Ive Bought another ZXR.....
Post by: Lord Danoir the first on April 07, 2015, 02:12:30 PM
I missed this thread...... update please me-laddo!!

chop chop
Title: Re: Ive Bought another ZXR.....
Post by: Bullet on April 07, 2015, 05:52:26 PM
Okies, update time! Might be a long post this one!

well It got fixed and ridden as cheaply as possible for a bit... which included fixing a knackard clutch slave cylinder and new seals on the master aswell, somehow it was still working! only symptom was it being a bit long travel on the lever, but the seal looked like this!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0029.jpg)

rebuilding the super spongy and binding breaks which comprised of new seals for the master cylinder again, and rebuilding / cleaning out the callipers where they had corroded behind the seals where it had sat for a few years, dremel is the tool of champions for this!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0070.jpg)

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0072.jpg)

I had to rebuild the forks yet again only this time using seals that cost more than a fiver as the the cheap ones really are a false economy!

I also managed to drop my fuel tank putting a dint in it  :angry: but the top needed respraying anyway as the previous owner stored it upside down with fuel in it which proceeded to leak out and destroy the paint, i bodged it just to stop it from rusting initially as my spraying is rubbish! tried to do a black panel on the top of the tank which kind of worked....

Dent:
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0385.jpg)

Filled/Sanded:
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0391.jpg)

Painted:
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0392.jpg)

made a boo boo!
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0393.jpg)

fixed it and lacquered it, Dont use the halfords petrol resistant lacquer, its crap, im never using it again!!!
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0416.jpg)

On the bike again, along with my nice cheapo fake carbon tank guard, knock off pazzo levers (£14.99 well spent!) and some crash bungs i also fitted.
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0501.jpg)

The first tank guard that arrived was broken so I tried my hand at plastic welding it having never done it before. It's actually surprisingly easy, but I got another one for the tank anyway.....
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0503.jpg)

And last but not least, I finally got a black screen, wanted a double bubble, but a new one is £££ and they dont seem to come up used.
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0628.jpg)

Meanwhile, whilst riding  this around and fixing its various niggles, Ive also been working on the front and rear end conversion ive had in the bag since i built the K model q plated thing dubbed 'project minja' by my non shiney bike hating buddies. figured i should probably use all the bits i had! so I finally got round to making the fitting kit i designed years ago, and getting the lower yolk modified to take the zxr bearings and grease seal.

Drawing:
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/zxr750%20zx10r%20spacers.jpg)

Finished bits:
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0143.jpg)

Test fitted on a spare frame in the lounge (its been being built in the kitchen, but no room to take a picture in there!)
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0321.jpg)

rebuilt, and resprayed the front callipers as the paint looked nasty, new hel lines front and rear. I got an 06 kit as I've got the radial levers off a zzr1400 to go on, so needed the lines to suit, annoyingly an 06 rear line is too short for an 04 so had to buy another one, oh well!
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0765.jpg)

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0771.jpg)

sanded down and resprayed a single seat tail unit I had left over from 'project minja' turns out it was an original one underneath the layers of paint! also sanded down a spare alloy tank I had left too. unsure if i should leave the tank bare alloy or spray it, i kinda like the bare metal look! I also got an 04 10r front fender from hong kong, its crap, nobody should buy these! buy the time you add import tax id rather have paid an extra £30 and got a carbon one in the uk!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0776.jpg)

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0779.jpg)

Trial fit.....
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0862.jpg)

Next problem was new lock stops, there in a different place on a 10r and also they the forks have a differant offset so hit the frame quite easily, and the fairing brace (not solved that problem yet!) so a good deal of measuring and drawing and cardboard mock ups arrived at this to bolt on the underside of the headstock where theres conveniently 2 bolt holes already!
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/10r%20lock%20stops%203.jpg)

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/10r%20lock%20stops%201.jpg)

the nice man at the machine shop said it would be 3 hours to make it, (£100 +) so kindly cut out the basic shapes for me for free, and i set to it with a drill, dremel, and a file!
(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0878.jpg)

so time to bolt it all on and solve the rest of the problems on the bike, I dont think the swingarm had EVER been removed on this thing, took me all day plus an assortment if increasingly bigger hammers and a blow torch to get it out, but finally out it came!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0879.jpg)

and now it looks like this!! It has revealed a couple of problems, the levers hit the clocks, but theyve got to be replaced anyway as the speedo drive was on the front wheel, ive got some 10r ones to fit. the throttle assembly hits the brake lines, so a zx636 one will be needed to fix that, and also the switchgear. the 10r also uses a longer and narrower chain so ive got one of those waiting to go on too :)

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_0886.jpg)

Title: Re: Ive Bought another ZXR.....Update page 3
Post by: Phil_8 on April 09, 2015, 04:55:39 PM
 :shocked:

*endless round of applause*
Title: Re: Ive Bought another ZXR.....Update page 3
Post by: Chojin on April 09, 2015, 08:58:27 PM
Christ, I wish I had the time/money/skill/inclination to do something like this!
Title: Re: Ive Bought another ZXR.....Update page 3
Post by: Bullet on April 13, 2015, 02:51:48 PM
cheers :) I think anyone could do it if they wanted to though, doesnt have to be expensive, or take as much skill as you might think! But time and inclination are unavoidable  ;)

Got the zx6r B1h throttle housing and cables today, all fitted but need to put a spacer in as the inner is slightly too long relative to the outer to adjust the slack out. got a ZX6r J start/kill/light switch too, same connectors but the cables are all in different places! you can pop out the spade connectors though and move them around & luckily the wire colours match the old switchgear so pretty straightforward to get them in the right place!  Its nearly rideable!
Title: Re: Ive Bought another ZXR.....Update page 3
Post by: Bullet on April 15, 2015, 09:40:16 PM
Throttle cable now adjusted perfectly thanks to a MTB brake adjuster, also had to replace the clutch push rod oil seal behind engine cover under the front sprocket, which is an engine out job thanks to some silly kawasaki designers! all went fine, done in record time, right up until putting in a new magnetic sump plug, which sheared off at almost no torque! damm thing!  :angry: I shant be using those again, now iv got to work out how to get the darn thing out!


edit, got it out now, thankfully some creative use of long nose pliers wedged in there did the job!
Title: Re: Ive Bought another ZXR.....Update page 3
Post by: Bullet on April 22, 2015, 08:10:35 PM
New chain fitted, new oil, fresh coolant, clutch bled with the new radial lever, warmed up.... had to take it for a little test ride around the block  :tongue: 

Its amazing the differance! feels so much lighter than before, I know in reality theres probably no more than 20lbs loss in weight but it feels more like 50  :cool:  the reduced offset has made it a bit faster steering and also drops into turns a bit below 30 needs pressure on the inside bar to hold a line, but that goes away once you go a bit faster  :moto: also I know the 10r 04 brakes got a bit of a bad rep, but honestly with the zzr1400 radial lever, these brakes are so sooooo much better than the old ones. radial lever for the clutch has taken it from being quite heavy to feather light too. So all in all, I'm well pleased! Now i just need to wire in the 10r clocks, thats going to be a headache because im crap at wiring! and make a new top fairing/mirror brace...
Title: Re: Ive Bought another ZXR.....Update page 3
Post by: Carbon_ZX6R on April 22, 2015, 10:09:01 PM
All sounding good , dont envy you with the wiring!
Title: Re: Ive Bought another ZXR.....Update page 3
Post by: Bullet on April 23, 2015, 11:23:57 AM
Im rubbish at it, its going to take me ages to get it right! I've got a helpfull pin out diagram for the clocks though and a wiring diagram for the zxr so hopefully I can work it out!

Already got the sprocket nut off a zx6r fitted so just need the speedo pickup sensor, and to mod the cover to take the sensor and to work out where it fits in relation to the sprocket nut :huh:  ........ and a speedo healer as im not running standard 10r gearing.  Actually thats quite alot!
Title: Re: Ive Bought another ZXR.....Update page 4
Post by: Bullet on June 24, 2015, 05:03:44 PM
Update time again, I've wired in the clocks, modified the mirror/fairing brace to take them and to clear the front yolk, and also mot'd it today! Yay!


wiring in the clocks was actually alot easier than I expected it to be as alot of the wires are the same colour, ordered up some connectors to match the original ones so I didn't have to chop up the existing loom, which was great in theory but the 10r clocks need a permanent live feed to remember the time, and also I had to combine the signal from both coils as my tacho was 50% out, so had to open up the loom in the end anyway, never mind!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_1077.jpg)
Clocks wired in but the tacho is 50% out as you can see by the idle speed. I gave up trying to con the fuel light into going out and took the clocks apart and blacked out the led in the end!

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_1084.jpg)
Wiring!!! Luckily I didn't have to go too far back into the loom to find a live feed, and the other coil pulse signal.


(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_1080.jpg)
And this is how you combine coil pulses without accidentally bridging the feeds and creating wasted spark....


(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/IMG_1097.jpg)
Modified fairing brace, the little tabs in the middle take the 10r clocks and the big curved bits replace the mirror brace. unfortunately theres too much spring in them so any bumps and you cant see anything in the mirrors! Plan is to just remove the mirrors and put a bar end mirror on, not ideal but should solve the problem!


So today it passed its mot finally, one advisory for a slack chain, its new & I've not adjusted it yet since its initial stretch. But here it is! Still looks a bit rough, but is the best handling, and certainly the best stopping ZXR I've ridden

(http://i47.photobucket.com/albums/f185/lsjbagpuss/bike%20randomness/Ninja%20zx10%20750.jpg)
Title: Re: Ive Bought another ZXR.....Update page 4
Post by: Carbon_ZX6R on June 24, 2015, 05:38:16 PM
coming along nicely , looks to  me like you have just chucked an old fairing over a much newer bike
Title: Re: Ive Bought another ZXR.....Update page 4
Post by: Farmer Giles on June 24, 2015, 08:10:00 PM
will you still need to sort the fuel gauge feed out or else it will just say 'fuel' all the time on the display.

Can you use another live feed to the fuel input on the clocks and then drop the voltage down to somewhere a little more than the empty level ? Im no expert but the output from the fuel sender will only be a voltage range so it just a case of working out the required voltage and dropping the feed accordingly..

Having said that I guess maybe it's not quite so simple or else you'd have done it.. 

2p
Title: Re: Ive Bought another ZXR.....Update page 4
Post by: Bullet on June 24, 2015, 08:18:29 PM
Quote from: Carbon_ZX6R on June 24, 2015, 05:38:16 PM
coming along nicely , looks to  me like you have just chucked an old fairing over a much newer bike

it does a bit yes, I don't think the new parts look too out of place though :)

Quote from: Farmer Giles on June 24, 2015, 08:10:00 PM
will you still need to sort the fuel gauge feed out or else it will just say 'fuel' all the time on the display.


I did try various voltage feeds into the fuel input and it didn't seem to make any difference :( thats when I gave up and blacked out the led.  It does flash "fuel" on the dash when you turn it on, but click the mode button and it goes away, still slightly annoying though. Whats higher up the to do list is to work out how to mount the speedo pickup sensor over the front sprocket and wire that and the speedo healer in, luckily you dont need the speedometer to actually work for an mot!  :shocked:
Title: Re: Ive Bought another ZXR.....Update page 4
Post by: Bullet on May 16, 2016, 08:00:51 PM
Time to dig up an old thread. I FINALLY fitted the 6r sprocket nut and speed pick up sensor to the sprocket cover, wired it all in, fitted a speedo healer and calibrated it..... It's only taken 11 months, but now the dash is fully functional and GPS calibrated  :cool:

next phase in the project is the 9r engine I bought years ago, and is sat under the stairs waiting for me to do something with it, come back in a year or two and i may have got round to it!