ZXR400H Rebuild
Posted: Fri Dec 09, 2016 12:35 pm
Ok, So I got this as my first bike back in 2007. It was very rough even at this early stage, I probably rode it for about 6 months and then had a minor off and parked it up in my garden for 8 years.
How it stood at this point,looking very sorry for itself. Iv'e had a few bikes in between but as this was my first bike and been neglected for so long I though it was time to give it a full rebuild. I have limited mechanical ability so I am learning as I go, I've also just become an apprentice for a large engineering company so i'm learning a bit at work as well. Ill try and get a photo of every stage, and if anyone wants any help on anything ive done just shoot me a PM and ill help if I can.
This was one of the main roadblocks for the project, most places that I took the bike to wouldn't attempt this repair,but I found a local fabrication company willing to give it a try. With this renewed confidence I set about fully stripping the bike.
With the frame stripped I could get it blasted ready for welding
Another slight issue was this bent sub frame, as a new one was 20 quid it was worthwhile replacing rather than repairing.
New subframe, new vs old,just a matter of swapping over all ancillaries
Getting the frame back from being chemically stripped at a local blasting/stripping firm (Midlands Coating Removal Process)
With all the paint removed the weld could be redone, for the pricely sum of £20.
Ready for powedercoating!
After a struggle all the bearings came out after years of siezing into place.
Subframe loosly bolted on to check fit, now the Swing arm needs new needle bearings. Whilst it is so far disassembled it is worth biting the bullet and getting it done now, not a bad lookign frame considering it is 26 years old!
Now I dropped the wheels (after tyres being removed by Sticky Lee, in Shifnal,Telford) off to be blasted and powder coated whilst I got on with the swing arm
New bearings for the frame and wheels
Driving in the new bearings-
All tourqued up to spec.
After a struggle, and more help from sticky lee the old headstock bearing races came out, the new ones went in much easier
New headstock bearings fitted after a slight clean of the tripple trees
Wheels picked up, going for what I believe is the original paint scheme, Red,Black and Ebony.
Old suspension was completely shot,so replaced with new where available.
Starting to get to know my powedercoater very well! With new bolts I can start to reassemble.
The rear shock linkage appears to be beyond recovery,so new bearings,o rings and seals ordered for a full rebuild, this is how it looked after 8 years of being sat in a garden.
And stripped for rebuilding
Ready for reassembly
Clearing out the excess powdercoating with a tap
New bearings and seals
Now assembled with the rear swing arm attachment arms,will hopefully be ok for another 26 years!
How it stood at this point,looking very sorry for itself. Iv'e had a few bikes in between but as this was my first bike and been neglected for so long I though it was time to give it a full rebuild. I have limited mechanical ability so I am learning as I go, I've also just become an apprentice for a large engineering company so i'm learning a bit at work as well. Ill try and get a photo of every stage, and if anyone wants any help on anything ive done just shoot me a PM and ill help if I can.
This was one of the main roadblocks for the project, most places that I took the bike to wouldn't attempt this repair,but I found a local fabrication company willing to give it a try. With this renewed confidence I set about fully stripping the bike.
With the frame stripped I could get it blasted ready for welding
Another slight issue was this bent sub frame, as a new one was 20 quid it was worthwhile replacing rather than repairing.
New subframe, new vs old,just a matter of swapping over all ancillaries
Getting the frame back from being chemically stripped at a local blasting/stripping firm (Midlands Coating Removal Process)
With all the paint removed the weld could be redone, for the pricely sum of £20.
Ready for powedercoating!
After a struggle all the bearings came out after years of siezing into place.
Subframe loosly bolted on to check fit, now the Swing arm needs new needle bearings. Whilst it is so far disassembled it is worth biting the bullet and getting it done now, not a bad lookign frame considering it is 26 years old!
Now I dropped the wheels (after tyres being removed by Sticky Lee, in Shifnal,Telford) off to be blasted and powder coated whilst I got on with the swing arm
New bearings for the frame and wheels
Driving in the new bearings-
All tourqued up to spec.
After a struggle, and more help from sticky lee the old headstock bearing races came out, the new ones went in much easier
New headstock bearings fitted after a slight clean of the tripple trees
Wheels picked up, going for what I believe is the original paint scheme, Red,Black and Ebony.
Old suspension was completely shot,so replaced with new where available.
Starting to get to know my powedercoater very well! With new bolts I can start to reassemble.
The rear shock linkage appears to be beyond recovery,so new bearings,o rings and seals ordered for a full rebuild, this is how it looked after 8 years of being sat in a garden.
And stripped for rebuilding
Ready for reassembly
Clearing out the excess powdercoating with a tap
New bearings and seals
Now assembled with the rear swing arm attachment arms,will hopefully be ok for another 26 years!