89 Zxr

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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fergy150
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Joined: Wed Apr 09, 2014 4:03 pm
My Bike: Kawasaki ZXR400H/ZX6RB1H
Location: Donington Park

89 Zxr

Post by fergy150 » Wed Feb 25, 2015 11:34 am

My zxr, came to me 3 different colours and a box of spare parts
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Managed to get it up and running for 30p! + price of mot (all it needed was a reflector)
This is it after changing front forks & rear shock for ones with custom springs/different internals, carbs changed, cleaned & balanced, exhaust swapped for a devil stubby, braided front lines and rebuilt all the calipers with new seals.
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Been riding it like this for about 6 months now or so now as I've been building my blade and decided to change it into a track bike!
Its off to the dyno later in the week to see how its running then gonna start messing about with the carbs, airbox, and got some track fairing waiting to go on, then gotta try make the exhaust a bit quieter biggrin

Plonk
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Re: 89 Zxr

Post by Plonk » Wed Feb 25, 2015 8:42 pm

Nice.....Exhaust quieter.....Really! :pmsl
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
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fergy150
Posts: 24
Joined: Wed Apr 09, 2014 4:03 pm
My Bike: Kawasaki ZXR400H/ZX6RB1H
Location: Donington Park

Re: 89 Zxr

Post by fergy150 » Wed Feb 10, 2016 8:42 pm

Got hold of some track fairing from the forum that was supposedly from an 88 zxr but for whatever reason it was just way to narrow to fit my bike (and practically falling to bits). Fortunately I still had my road fairing so with some help from some fiberglass and body filler this happened.

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And with some random green spray cans looked like this

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Managed to get hold of a quickshifter off ebay

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Got it all wired in and connected up ready for track day apart from the small matter of getting of actually getting the engine running (had been sat for 3 months at this point).
With some swearing and easy start got it running beautifully at the track, but for the life of me could not get the damn quickshifter to work while it was moving.

fergy150
Posts: 24
Joined: Wed Apr 09, 2014 4:03 pm
My Bike: Kawasaki ZXR400H/ZX6RB1H
Location: Donington Park

Re: 89 Zxr

Post by fergy150 » Wed Feb 10, 2016 8:58 pm

Then the problems started...

Second session out happen to glance down an the temperatures reading off the dial, so I come in and bike starts emptying its coolant out all over the paddock, afterwhile it stops so topped her back up with fluids and carry on, the rest of the day carrys on much like this but she still keeps on going and being very rev happy :excited

Not only that like a right plonker putting the bike back on the trailer got stuck halfway up the ramp, fell off and cracked the rearset so much so it was pretty much in 2 bits :smt011

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Consensus in the paddock was that my radiator hoses are well past there prime (they do look and feel ancient) so next got hold of a samco hose kit to try and help with its cooling problem.

While I was fitting this I just happened to take the water pump apart (held together with more instant gasket than I've ever seen) to find this...

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Found out that water pumps are like gold dust, lots of covers available but hardly any water pumps. Fortunately local bike breaker had a ZX4R and even though its a different engine turns out their water pump is identical :smt003

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While I was doing this thought it would benfit from a nice shin new chain an set of sprockets

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Got it all back together at just in time for another trackday

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Went a lot better this time with it only losing massive amount of coolant when I stopped and turned the engine off
Last edited by fergy150 on Wed Feb 10, 2016 9:16 pm, edited 1 time in total.

fergy150
Posts: 24
Joined: Wed Apr 09, 2014 4:03 pm
My Bike: Kawasaki ZXR400H/ZX6RB1H
Location: Donington Park

Re: 89 Zxr

Post by fergy150 » Wed Feb 10, 2016 9:08 pm

Since it kept throwing its guts up and not wanting to destroy her anymore it was time for a strip down and rebuild

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took the engine out ready for to sort her out

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Head and piston barrels ready for inspection/damage assesment

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I was then taking the bit off the head that the small 90 degree pipe from the water pump goes in to and look what I found semi-blocking the holes

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So now I at least know what happened to the rest of the water pump!

Next the heads getting a port and a polish, valve seats re cut, new oil seals (as the old ones are leaking quite badly), new valve springs (the olds ones have got 4-5mm deep grooves in them from the valve spring seats or whatever they're called), new piston rings, new cam chain and tensioner and new headers.

O and RMKD gave me the idea that an R6 shock is a good upgrade for the rear as mine needs a rebuild so promptly found a shock from a r6 thats never been used :excited

More to come soon I hope!

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banner001
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Re: 89 Zxr

Post by banner001 » Thu Feb 11, 2016 9:10 am

looking alright that :D

1988 front fairing is from a zx4g..hence why it didnt fit btw...
UK ZXR400 L3 (1993) - Fully restored and on the roads, my green beast!
JPN ZXR250 A2 (1990) - Revs to 19,200rpm... 'nuff said :smt003

richyrd5
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Re: 89 Zxr

Post by richyrd5 » Thu Feb 11, 2016 9:23 am

What year r6 shock fits fergy... smiler

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masterofinsanity
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Re: 89 Zxr

Post by masterofinsanity » Thu Feb 11, 2016 1:21 pm

great thread, keep it updated !
Don't forget people there is more to the zxr400 than this forum... check out www.zxrworld.co.uk also.

fergy150
Posts: 24
Joined: Wed Apr 09, 2014 4:03 pm
My Bike: Kawasaki ZXR400H/ZX6RB1H
Location: Donington Park

Re: 89 Zxr

Post by fergy150 » Tue Feb 16, 2016 10:41 am

1988 front fairing is from a zx4g..hence why it didnt fit btw...
ahhh that explains a lot!
richyrd5 wrote:What year r6 shock fits fergy... smiler
I've got a 2006 one but when I fit it (if it fits) I'll post pictures on how I did it/any modifications I had to make

richyrd5
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Re: 89 Zxr

Post by richyrd5 » Tue Feb 16, 2016 10:52 am

:excited top man

Top-shaggy
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Re: 89 Zxr

Post by Top-shaggy » Wed Feb 17, 2016 8:18 am

Great thread and pictures :)
We are we're we are..

richyrd5
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Re: 89 Zxr

Post by richyrd5 » Wed Feb 17, 2016 9:06 am

Yup...good thread..i look forward to reading more of this.. winks

zxr400H_297
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Re: 89 Zxr

Post by zxr400H_297 » Sun May 15, 2016 12:12 pm

What rear end is that ? was it easy to fit?

fergy150
Posts: 24
Joined: Wed Apr 09, 2014 4:03 pm
My Bike: Kawasaki ZXR400H/ZX6RB1H
Location: Donington Park

Re: 89 Zxr

Post by fergy150 » Wed May 18, 2016 12:53 pm

zxr400H_297 wrote:What rear end is that ? was it easy to fit?
Its just a race seat unit, it did fit straight on to mine but could really do with an undertray to finish it off

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