L9 Rebuild

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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mark400
Posts: 210
Joined: Fri Feb 06, 2009 11:48 pm
My Bike: Building an original SP

L9 Rebuild

Post by mark400 » Thu Jan 15, 2015 11:48 pm

Bought this L9 in 2008

Just bought the first set of parts back from the shed - 1st step will be powdercoating the frame and swing



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Last edited by mark400 on Mon Aug 01, 2016 12:29 am, edited 1 time in total.
NG Road Racing Champion 2012 400SS

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mark400
Posts: 210
Joined: Fri Feb 06, 2009 11:48 pm
My Bike: Building an original SP

Re: L9 Rebuild

Post by mark400 » Wed Jan 28, 2015 7:45 pm

Just received the frame & swinging arm back from the powercoaters, have fitted new swinging arm bearings and now chosen a ZX6R shock upgrade ( as my brother has fitted an Ohlins to his race bike it was surplus to requirements).

The ZX6R shock has a smaller diameter top & bottom bush than the ZXR400, so to address this, I drilled the lower mounting holes in the shock out from 10mm to 12mm. For the top, I just used the ZX6r mount, which fits in the ZXR400 frame beautifully, but needs about 2mm taking off in order to fit. I did this with a saw.

The shock is now in, so I'll need to check where the top reservoir sits in comparison to the battery box - I suspect I'll need to modify the battery box and lose 3-4 cm, but the NC30 battery works well in my race bike, and is about 3-4 cm smaller, so I'm confident this will be a quick fix.

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Last edited by mark400 on Fri Jan 30, 2015 12:54 am, edited 1 time in total.
NG Road Racing Champion 2012 400SS

JamieNeve
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My Bike: CBR600RR, ZXR400 L-2
Location: Waterlooville, Hampshire

L9 Rebuild

Post by JamieNeve » Wed Jan 28, 2015 10:26 pm

Looking good, love the look of freshly powder-coated metal!

ChowderV4
Posts: 97
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My Bike: Zxr400L racer

Re: L9 Rebuild

Post by ChowderV4 » Thu Jan 29, 2015 5:51 pm

i like the option you took with the top mount.
I fitted a gsxr shock to mine and drilled the bottom out the same, but with the top i filled the zxr top mount holes with weld then ground flat and redrilled the correct size.....your idea looks far quicker aha

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mark400
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My Bike: Building an original SP

Re: L9 Rebuild

Post by mark400 » Fri Jan 30, 2015 12:59 am

I have also fitted a GSXR K7 shock into a ZXR400 Race bike as well, but I pressed a different top bush in so that the ZXR Bolt & mount fitted. The shock was re sprung at Maxton and then set up by BMC racing at the track and I think the bike still holds a few lap records with NGRRC.(Ben Ireland) I think most Suzuki and Kawasaki shocks fit quite well as they have the fork / prongs type lower mount.
NG Road Racing Champion 2012 400SS

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mark400
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My Bike: Building an original SP

Re: L9 Rebuild

Post by mark400 » Mon Feb 02, 2015 1:13 am

Re-cutting the threads to mount the footpeg hangers

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NG Road Racing Champion 2012 400SS

titi bzh
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My Bike: ZXR 400 L2

Re: L9 Rebuild

Post by titi bzh » Mon Feb 02, 2015 6:14 am

Hi

Nice thread

Thierry

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Re: L9 Rebuild

Post by Top-shaggy » Mon Feb 02, 2015 8:26 am

I'm amongst the lurkers.. But really enjoy hearing about people's projects .. Especially with pictures .. Great thread
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Plonk
Posts: 46
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My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: L9 Rebuild

Post by Plonk » Mon Feb 02, 2015 7:55 pm

Speaking to my mate who powdercoats, they have hundreds of rubber cones that they can use to plug all bolt holes. If they don't use them, they are plain lazy! Having said that, I have had to re tap all my threads to... :smt009
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
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ZXR400 H1 Restoration project

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mark400
Posts: 210
Joined: Fri Feb 06, 2009 11:48 pm
My Bike: Building an original SP

Re: L9 Rebuild

Post by mark400 » Thu Feb 05, 2015 9:42 pm

Rolling chassis. Next step will take longer

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Last edited by mark400 on Mon Aug 01, 2016 12:28 am, edited 1 time in total.
NG Road Racing Champion 2012 400SS

Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: L9 Rebuild

Post by Plonk » Fri Feb 06, 2015 11:56 am

Looks good so far, the 600 shock looks sweet to. Just removing the black powdercoating from my frame...... Cue white finger syndrome!
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project

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