New l2 project

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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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

New l2 project

Post by ninjadave1400 »

Hi guys I'm about to take delivery of my zxr I thought I would post some pics as it is now,
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

And 1 more
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

so go the bike in the work shop and set about finding what was broken and what was save able.
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and there was a fair bit of damage some i had spotted some was a supprise.
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so next i had to start fixing what i could the mirror mount was bent, and was easily straightened with a vice and some brute force will need painting later thought.
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same story with both mid fairing brakets,
before.
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and after not perfect but much better.
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

Calipers

having decided to change out all brake hoses for hel braded lines, pulling the caliper to cure the binding was a chance that was silly to miss, and boy were there some horrors.
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once i split the first caliper i found the pistons were siezed and there were anti-squiel pads in them these turned out to be a massive help on getting the pistons out, i drilled a 5 mm hole through them put a screw in and used a slide hammer to get them out i had to do this on all 8 and i still didnt take a picture :smt011

once out it was obvious the fluid was past it and one side had no dust seals in place meaning the fluid seals were weeping,
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they are now nice and clean and waiting on new pistons and seals which i am hunting for as the best i can find is £72 per caliper.

i then removed the tail section to fit the new indicatos from bike it, and found quite a mix of fixings had been used.
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old indicator.
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and the new shiney one
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rocco
Posts: 8
Joined: Sun Oct 06, 2013 5:27 pm
My Bike: zxr 400l3

Re: New l2 project

Post by rocco »

Fair play to you mate..... It looks like you've been busy!!!
ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

2 days work I'm quite chuffed need it on the road ASAP will prob do body work next winter, once I have decided on a colour scheme.
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

so got up very early today and pulled the hose off and drained the coolant will flush rad tonight.
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came out clear and with no sign of coolant I'm slightly concerned but a new set of Samco hoses on the way and some proper coolant I'm hoping to hit no issues with the cooling system.
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

got to work and in with the parts for the company, some bits for the zxr, new brake lines and a clutch cable.
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

clutch cable

once the old cable is off this can be done any way you like, how ever the refit i have documented in case any one is a little worried about doing it, firstly we need to oil the new cable.
its a small hole but with care you can get oil in there i use a steady hand and an oil can i keep going untill oil drips from the botttom this way i know ive done my best to maximise the life of the cable.
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next there are 4 places the cable must run through, 3 guides and then the lower adjuster,
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getting it in to the arm can be fiddly how ever persistance will out
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next i had to re assemble the lever this just slides together with some grease,
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cable just slides in its easier to do this first,
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next it slips through the adjuster and into place in the lever mount,
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slide through bolt in and tighten now adjusting the cable is simple, i like to take the lower adjuster all the way to the end and use the upper adjuster for fine tuning i hit a snag in that my clutch plates are stuck together meaning i cannot check the clutch isnt dragging untill i strip it out.
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

Rear Hel Brake Line

the pictures tell the story i only need to add that a vacume bleeding tool is a god send and banjos should be tightened to around 20 foot pounds.
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

various job firstly dropping the oil
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does any one know what should be in these holes rather than tape ??????
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Columbo
Posts: 77
Joined: Thu Jan 03, 2013 1:26 am
My Bike: ZXR 400 L9

Re: New l2 project

Post by Columbo »

Those holes should be filled by rubber bungs. Easily visible in the parts diagram.

92066A - http://www.kawasakioriginalparts.com/ka ... 1999&ca=GB
ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

ahh i was staring at that epc page for ages never spotted them :smt011
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ninjadave1400
Posts: 37
Joined: Fri Jan 17, 2014 1:27 pm
My Bike: zxr400

Re: New l2 project

Post by ninjadave1400 »

right today the piston and seals arrived for the front calipers i upgraded to stainless steel to try and maximise the life of them the pictures tell the story,
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i would have re-fitted them but i forgot to pick up my o-ring set from my uncles place so i will finish this job tomorrow, also today my bike skate arrived :excited
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once on the skate i striped the clutch apart to investage the issue and found some issues, im having one of the race techs at work take a look but im thinking i will replace it all including springs, and also a fair bit of moisture in threre but im thinking that may be where its been sat for ages.

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Gemini
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Re: New l2 project

Post by Gemini »

red rubber grease in the calipers, good man

i used to swear by that stuff on my 7r!

gem
There's No Explanation For The Way I'm About To Behave!!!
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