banner's beast...

Here's a chance to show off your zxr400, so get them digital cameras out and show us some piccies.Rebuilding your bike or modding it then let everyone in on it.

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banner001
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Re: banner's beast...

Post by banner001 » Tue Feb 21, 2017 10:04 am

aye, at 50k miles i think its time for a bit of love :D

i have finished my prep of my donor swingarm, it had a snapped paddock bobbin holder...never liked them, and wont be using them so ive removed the one on the other side and ground down the welds so they are at the same level as the ones nearby...so you will never notice the difference.

ive also removed the generator cover so my powdercoater can get the correct RAL number for the generator cover...im having all the engine covers done in the same colour so they all match...havent asked for a price...it costs what it costs :smt010
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Sun May 07, 2017 3:58 pm

Been cleaning my downpipes, many years of snow rain and salty roads had started to take its toll, if only superficial, and needed addressing.

I have pictures, but I'll have to add the links once I get on a computer.

Method is to use harpic power max 10 bleach as it's got a good bit of hydrochloric acid in it and that's what eats away at the surface rust. Smear it all over the downpipes and leave for 5 minutes. Take a green scourer pad, add some of the bleach to that and give your pipes a damn good scouring to remove the rust, then wash liberally with water, repeat if necessary then a bit of wet-2000 grit wet and dry sand paper to even out the pipes, then follow up with autosol...stand back and admire your handwork.

Pipes went from this:
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To this:
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was only surface rust, and some very minor pitting, nothing too major, but feels good to have got all that crap off it :excited
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Mon May 08, 2017 12:59 pm

and yes, the cats litter tray was emptied by the wife soon after this picture was taken :D
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Wed May 10, 2017 1:26 pm

i seem to remember someone asking me where i got the decals for my bike from...i have just found the email trail...they were from Sunrise Graphics, the WEBSITE is currently a bit dodgy, but he has a more comprehensive pricing list HERE.
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Tue Jun 27, 2017 1:59 pm

Not my 400, one of my other projects thats now on the go, a 20bhp racing scooter engine in my original malaguti frame that ive chopped, stretched and lowered...

This is how it currently looks:
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Im sorting out the engine placement, electrics, switch gear, lighting and cooling at the moment, then i can weld up all the mounting points and hopefully make it rideable soon, will be fun, almost 90mph on 12" wheels :D Im hoping to keep the bike weight under 50kg fuelled, 40kg would be awesome for a 1:2 power to weight ratio but as all the mountings are steel im not sure...

Image

Image

Image

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going to go with an early r6 seat unit, a ~6-10L fuel in frame brace between the frame and headstock, the smallest battery i can find to go under the seat, and all the electrics will be mounted to the engine mounting plate as in the picture except the switchgear, water pump and lights. should be fun until the engine blows up :D
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

realnuts
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Re: banner's beast...

Post by realnuts » Thu Jul 06, 2017 8:25 pm

hi
i love the work on your exhaust pipes. Sandybikespares no longer exists, it is black widow now.
Happy about the performance of the exhaust?

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banner001
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Re: banner's beast...

Post by banner001 » Sat Jul 08, 2017 9:56 am

Yeah, no worries really, I had to change mine as the mild steel originals were beyond rusty, and I preferred the look of the SBS ones over the delkevic aftermarket ones. I've not noticed any performance gains, if you want to go down that route you need to go for beet pipes, or make your own.
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Fri Aug 25, 2017 12:40 pm

My parts are back from the Powdercoaters...took 6 months but they look amazing! I'll post pictures when I get on a computer. Have no money for any other bits so will fettle these and get them all ready for when I need them, i.e. cleaning off any overpower, tapping all the screw holes to remove the dust from the blasting cabinet etc.

The rebuild can soon begin.
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Fri Aug 25, 2017 9:56 pm

Ive gone for 3 different colours, basically identical to the original bike, silver for frame, grey for covers and black for ancillary parts
Image

Image

Image

Image

Image

:excited
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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masterofinsanity
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Re: banner's beast...

Post by masterofinsanity » Mon Aug 28, 2017 6:53 am

nice!! love what you did to the downpipes, might have a go at mine.
Don't forget people there is more to the zxr400 than this forum... check out www.zxrworld.co.uk also.

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banner001
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Re: banner's beast...

Post by banner001 » Wed Jul 18, 2018 8:03 am

Things are starting to happen...have bought all brand new bearings, seals, bushes etc... and brand new A2/A4 stainless steel bolts, flange it's, dome nuts etc... Just need a new shock and it can go back together.

Have prepped all the Powdercoater parts, they just need the bearings pressing in now, then a new shock needs to be bought...and it can pretty much get bolted back together...can't wait!

I've got a low mileage donor engine to put back in it, my original one is going to get a 444cc kit, adjustable cams, flatslides, a full dynamic balanced bottom end, lightened and knife-edged crank and a superfinished gearbox...it will be kept as a project engine and will still give me a good working one on the bike.
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Fri Jul 20, 2018 8:11 am

Image
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Mon Jul 23, 2018 2:35 pm

All bearings are in, all seals are in, everything has been greased or coperslipped as necessary.

All bolts have either been cut to length, or capped with dome nuts, everything is minimum A2-70 stainless steel
Image

The captive nuts in the back part of the hugger had spun in the plastic and we're proper knackered, so I've cut it all back and can now get a washer and dome nut on it instead...still don't know what Kawasaki didn't do it as standard...
Image

Have fully taken the clocks apart, and given them a full clean
Image

And when I say fully taken apart...
Image
I even popped the coloured plastic squares out and cleaned all that :D

Current state of the bike
Image

Am missing a few parts that I forgot to order, when they are here I can get the back end on and it will start to look more like a bike!
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Mon Jul 23, 2018 10:40 pm

Wonder no more about the inner juices of your rear seat lock...

Image
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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banner001
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Re: banner's beast...

Post by banner001 » Fri Jul 27, 2018 4:20 pm

Engine is now in...
Image

progress might slow slightly as im waiting for funds to buy the rear shock, and need a few small bits here and there for the rear of the bike mainly.

Hoping to build up the front end soon and get it standing on 1 leg :D
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

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