How to turn a Zorst into a Bike

[carsounds_dan]

you could even go down fuel injection... i tryed but then found that the aftermarket ecu manufacturers all say "programable to 20000rpm" but actually mean "tested to 12000, the ecu SHOULD be able to cope with your 15500 rev limit though... kinda". which is all great but at £400-500 for the ones i was looking at its a big investment for a bike only worth £1200 and then a worthless investment if it don't work.. now fuel injecting my sv is different of course... gotta love the low reving twin.
as for the iginition box i'd go aftermarket or get yours modded. to get the most out of the sp one you'll need flat sides because fitting a tps on your normal cvs wont really do much there are plenty of bits of kits available to map ignition curves... if you need engine bits let me know.. ive got one in bits im trying to sell in my garage lol
cheers
dan

[Mori Man]

Thanks for the feedback guy's.

Already have the flatslides with TPS (inlet's and cables too).
Got the CDI unit (SP)

priced a new loom and advancer at under £85 so not a sore development.

lookin at a total of £275 if i can't source a used loom.

Cam's are under £200 new.

If I make 5 BHP extra with that lot at that budget I will be well happy (£100 / BHP) but hoping for 7-9 BHP

New exhaust system arrives tonight to give something to "bounce" the BEET system off

[Mori Man]

Bike gets delivered in about 2hrs time - getting a bit excited

Should also secure another zorst tonight

[zimm]

Xmas every week at yours by the sounds of it Drew

just out of interest .. have you ever ridden a zxr400 ?

[masterofinsanity]

you must be exzorsted with all this chopping and changing?

[Mori Man]

Xmas every week at yours by the sounds of it Drew

just out of interest .. have you ever ridden a zxr400 ?

nope

More like every day - had 20yr old rear Ohlins delivered - NOS

A kerker for a 1982 GPz550 that has a badge on it that's about 8mm thick - Built in crash bung ! They new how to make badges back then

[Mori Man]

you must be exzorsted with all this chopping and changing?

The fun begins tomorrow - got a stock of gaskets in

[Mori Man]

It's done a whopping,

20,552Km = 12,845 Miles

Brakes are fine, chain and sprocket look OK, discs are fine

What I've seen so far, air scoop hoses- shot, small crack at front of fairing, missing rear indy lens, scuff on rear seat panel (Left side) some scuffs here and there.

daylight brings a different story though

[zimm]

sounds like a bargain mate !

you dont need a gofer do you ? im prepared to work for unobtainium

[Mori Man]

sounds like a bargain mate !

you dont need a gofer do you ? im prepared to work for unobtainium

Could do with a Boxer/Packer, got a freakin bedroom full to the ceiling!!

[Mori Man]

Had a day off work and got on with some spannering
As suspected the light of day revealed all
Actually not that bad, and i have bought worse for more in the past
Started a 10am and by 3pm the bike was running
Couldn't get it to tickover right but that's more than likely to do with the carbs more than anything else - they were seriously furred up and ideally should of went into a sonic bath to get them back in tip top condition. But I got them clean enough to hear the motor and I have the FCr's for the re-build
Good news was not a puff of smoke (apart from carb and parts cleaner for a few sec's) and once warm fired up no worries
Engine oil is clean, like not changed that long before stopping to use the bike clean. Took one plug out before the 1st turn over and it looked clean enough too.
On strip down the standard filter had crumbled into dust and filled the airbox and carbs up - so was glad i never attempted to get it going before stripping it
Nothing seized and everthing came of just fine.
Forks are in great condition apart from needing over hauled - they are bette than my SP's - anodizing is cleaner, tubes have only a few minor pits low down and the silver paint is fully intact. Front brakes are also working no prob's.

The bad bit's of the bike are cosmetic which will be sorted and the rear shock is leaking so it will get binned for something else








Once the plastic was off;


Inside the box;


Inside the carbs (not as bad lookin as they were as I had already drowned them);


getting them cleaner;


What started it all off;

[Mori Man]

[RedexRobB]

wow, well done. It sounds a bit like mine does in that last video, mine turned out to be plugs but going by the state of the carbs they probably just need a damn good clean!

[Mori Man]

wow, well done. It sounds a bit like mine does in that last video, mine turned out to be plugs but going by the state of the carbs they probably just need a damn good clean!

Reckon the emulsion tubes and the PAJ's still have green crud inside I cant get too, the FCR's will soon sort that , cables haven't arrived yet or they would of been on straight away and saved me a few hours

Was great to hear it fire up though

Now to get time to dismantle and rebuild

[Mori Man]

SP cam's arrived tonight and are almost minted

One intake lobe has a very small pit - crtainly nothing to write home about

Removed the end can of the BEET today and fitted it onto my ZRX - holly molly what a difference !

Start off, it's a whole lot quieter

Initial take off has a punch but rapidly looses that and you feel it holding the bike back, further up - say around 9K it comes back on again up to the rev limiter.

Very smooth throughout but too restrictive, laying on the power at rev's I know should go ballistic made me feel I had my CVK's back on

Conclusion: When re-building it will more than likely get my ZRX's BEET end can - fitted it up today and it looked nice , depending on my final colour scheme there is another option

FCR cables arrived tonight along with the inlet rubbers, unfortunately working this weekend so no opportunity to put them on until Tuesday

Next will be clearing my spare bedroom out and getting all the parts dismantled off the bike.

1st Decisions:

Frame and arm will get the paint stripped off , the main beams will then get a Carbon Fibre shell applied with all other areas sprayed Satin Black

Two choices:

Apply the carbon fibre myself

Buy genuine sheets of self adhesive carbon fibre - very nice stuff

Wheels are going to be all Black with a Lime green coach line - might be OEM but i do have a set of Marchesini's in the cupboard doing nothing Can get the necessary reducers and spacers to make them fit but can't see a 6" rear rim going in there Need that Xanthus arm to suss it out

Will more than likely come down to a "time" factor as i want to set a goal to have this done by otherwise it will keep getting put aside as my work load increases. Just now it's all too easy to get pulled into work 7 days a week and i have to step back from that and create my own time again. It's the main reason I actually got this to work on, as my ZRX is nearing completion and requires very little much than polishing every now and again.

Still looking for a "Ram air" box but this is also looking promising (I would put SS meshes on the trumpets the same as my TMR's )





Later.....