ZXR400M1 rebuild - finally !

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.

Moderator: Moderators

User avatar
Mori Man
Blingmeister
Blingmeister
Posts: 1976
Joined: Thu May 10, 2007 3:30 pm
My Bike: ZXR400J2
Location: JAPAN

ZXR400M1 rebuild - finally !

Post by Mori Man »

Well it's been sat in the shed for near on 2yrs vsad

Finally I've started to do something with it biggrin

Kawasaki UK asked to do a feature on me with my bikes so I pulled the sheet off it and washed it down , it cleaned up pretty good and after scoring an as new cowl and side cowls from a M3 my mind was made up to get it on the road again.

Image
Image
Image

The M1 came with no paperwork so I had to get another frame with documents , as luck would have it I sourced one for a member here and had it shipped to Australia. An email or two later and they agreed to swap it for my frame and on a holiday trip here they brought it back :smt004

So it got stripped and painted, and has kicked about my store rooms for 18 months :smt009

Paint stripper that actually works !

Image

Image

Image



I took some general photos of the bike before stripping down as a guide for rebuilding , sorry but I haven't done in depth shots of the build as it's cold out there and washing my hands every 5mins to take a pic is just going to slow things down to much.

Image
Image
Image
Image
Image
Image


I was just going to do a straight swap over job but it would pain me to put dirty manky parts back on so everything is getting a good wash n polish - no resprays though as no time and too freakin cold. I can't locate all the parts I have for it as mostly buried in the store rooms but the OEM box was at hand with new parts in there so pads, chain, indy's and the like all renewed. As I unearth rear sets and the like they will get bolted on at a later date.

Swing arm got all new bearings
Image
Image

Fitted it up with ride height adjusters
Image

Fitted a rocker with grease nipples
Image

Set the valve clearances
Image
Image

Engine and front end with new frame
Image
Image
Image

KRT spring fitted to SP shock
Image

Callipers scrubbed to within an inch of their lives !
Image

Wheels on with new boots
Image

Stop n Go action
Image

New filter & fuel line
Image

BEET Ti zorst fitted
Image
Image

Sticky rubber
Image
Image

Streetfighter in the making :smt002
Image

Front end completed and M4 tank fitted to see how it would look
Image
Image

All going to plan I should fire up the engine this weekend and get it booked in for it's MOT by the end of the month :smt003
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
User avatar
Mori Man
Blingmeister
Blingmeister
Posts: 1976
Joined: Thu May 10, 2007 3:30 pm
My Bike: ZXR400J2
Location: JAPAN

Re: ZXR400M1 rebuild - finally !

Post by Mori Man »

A bit more done , suddenly looking like a bike again :smt001

Loom fitted and mostly plugged in , just to zip tie it in place.
Image

Rusty bolts swapped out for stainless
Image

Image

New inlet manifolds going on , never a bad thing to do and the old ones are rock hard anyway

Image

Fluids all done
Image

Image

Not sure if this can will stay on , got a selection but until the rest of the bike is built it will stay just now
Image
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
User avatar
banner001
Track day God
Track day God
Posts: 2585
Joined: Sat Sep 24, 2011 3:27 pm
My Bike: ZXR400 L4
Location: Nuneaton

Re: ZXR400M1 rebuild - finally !

Post by banner001 »

yay! mori-man is back!

good looking bike :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
kawazonkey
Posts: 102
Joined: Mon Oct 07, 2013 11:54 pm
My Bike: Kawasaki zxr400

Re: ZXR400M1 rebuild - finally !

Post by kawazonkey »

I am not in the slightest bit jealous of those bikes, no, not at all.

Looks effing brilliant!
Leey
Posts: 138
Joined: Sun Apr 17, 2011 11:23 am
My Bike: Zxr400L8
Location: gloucestershire

Re: ZXR400M1 rebuild - finally !

Post by Leey »

Top class as always mori-man as said before jealous of the parts you seem to be able acquire.
User avatar
wilko
Posts: 50
Joined: Sat Aug 25, 2012 12:14 pm
My Bike: zxr400 L1 & R1 4c8
Location: north east

Re: ZXR400M1 rebuild - finally !

Post by wilko »

You have some lovely looking bike looking forward to seeing this one built up :-)
Life’s journey is not to arrive at the grave safely, in a well preserved body, but rather to skid in sideways, totally worn out, shouting ‘Holy toad, what a ride!
tink
zxr400 oc member
zxr400 oc member
Posts: 230
Joined: Fri Sep 16, 2011 11:55 am
My Bike: ZXR400 L2
Location: Nuneaton

Re: ZXR400M1 rebuild - finally !

Post by tink »

Wow very nice
User avatar
Mori Man
Blingmeister
Blingmeister
Posts: 1976
Joined: Thu May 10, 2007 3:30 pm
My Bike: ZXR400J2
Location: JAPAN

Re: ZXR400M1 rebuild - finally !

Post by Mori Man »

Well that's it a runner again :excited

Has started flawlessly over the past 4 hrs with 6 full heat cycles and fan on many times. Clutch is nice and quite and engages gear with out to much transmission " Clunk "

Glad I put the ride height adjusters on - up on my tip toes with them at standard shocking For a bike that looks compact , it's tall !

Will have some video of it soon , didn't do one with the tank on but these photos were taken while it was running :smt001
IMG_4176.JPG
IMG_4177.JPG
You do not have the required permissions to view the files attached to this post.
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
User avatar
Mori Man
Blingmeister
Blingmeister
Posts: 1976
Joined: Thu May 10, 2007 3:30 pm
My Bike: ZXR400J2
Location: JAPAN

Re: ZXR400M1 rebuild - finally !

Post by Mori Man »




Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
User avatar
Mori Man
Blingmeister
Blingmeister
Posts: 1976
Joined: Thu May 10, 2007 3:30 pm
My Bike: ZXR400J2
Location: JAPAN

Re: ZXR400M1 rebuild - finally !

Post by Mori Man »

Almost finished :smt003
IMG_4178.JPG
You do not have the required permissions to view the files attached to this post.
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
copeyhagen
Posts: 58
Joined: Mon Mar 26, 2012 10:10 am
My Bike: zxr 400

Re: ZXR400M1 rebuild - finally !

Post by copeyhagen »

how many 4's do you own?!! :smt004
User avatar
masterofinsanity
Site Admin
Site Admin
Posts: 8101
Joined: Thu Aug 29, 2002 12:36 am
My Bike: Aprilia Tuono Fighter
Location: England
Contact:

Re: ZXR400M1 rebuild - finally !

Post by masterofinsanity »

makes me want to buy another zxr400 !! :smt110
Don't forget people there is more to the zxr400 than this forum... check out www.zxrworld.co.uk also.
User avatar
Mori Man
Blingmeister
Blingmeister
Posts: 1976
Joined: Thu May 10, 2007 3:30 pm
My Bike: ZXR400J2
Location: JAPAN

Re: ZXR400M1 rebuild - finally !

Post by Mori Man »

masterofinsanity wrote:makes me want to buy another zxr400 !! :smt110
Never a bad idea :smt003
copeyhagen wrote:how many 4's do you own?!! :smt004
Good question ! :smt017 Maybe seven , got nine engines so just need to count how many frames I have geek
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
ZX4R-F3
Posts: 95
Joined: Thu Jan 13, 2011 1:03 am
My Bike: 1988 ZX400-F3
Location: Ashton-u-Lyne

Re: ZXR400M1 rebuild - finally !

Post by ZX4R-F3 »

Very nice indeed.
Where did you source the ride height adjusters from, if you don't mind me asking, they look very similar to the Ducati ones.
Keep up the good work.
[b][color=#FF0000]If your not living on the edge, then your taking up to much room.[/color][/b]
User avatar
Mori Man
Blingmeister
Blingmeister
Posts: 1976
Joined: Thu May 10, 2007 3:30 pm
My Bike: ZXR400J2
Location: JAPAN

Re: ZXR400M1 rebuild - finally !

Post by Mori Man »

ZX4R-F3 wrote:Very nice indeed.
Where did you source the ride height adjusters from, if you don't mind me asking, they look very similar to the Ducati ones.
Keep up the good work.
Kit for GPz900
Nothing worse than having an H and not being able to scratch it !
Living life on the edge, SuPposedly
Post Reply