www.zxrworld.co.uk

My zxr, came to me 3 different colours and a box of spare parts

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.


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

Nice.....Exhaust quieter.....Really!

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.



And with some random green spray cans looked like this



Managed to get hold of a quickshifter off ebay



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.

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

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



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...



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



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



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





Went a lot better this time with it only losing massive amount of coolant when I stopped and turned the engine off

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



took the engine out ready for to sort her out



Head and piston barrels ready for inspection/damage assesment



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



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

More to come soon I hope!

looking alright that

1988 front fairing is from a zx4g..hence why it didnt fit btw...

What year r6 shock fits fergy...

great thread, keep it updated !

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...

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

top man

Great thread and pictures

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

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

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