ZXR400L1 mini Refurb (see what winter does to your bike!!)

[RedexRobB]

Someone here re did thier nuts and bolts in some plating, forget the name of it now and who it was. kwakkev iirc.

[WelshD1K]

'nitro' rear shock ?

[arkell]

Been in spain for couple weeks (hard life eh!) so havnt been up to much, finished painting the subframe before i left so got that on when I got back;

Put some carbon fibre effect sticker on the areas where the seat rubs and caused paint to flake before, so hopefully it will help



Also added some white rim tape- gonna have to wait until fairings are back on to see how it looks in the flesh!



Polished up some bits, footrests and exhaust hanger, not the best job but major improvement

before

After

Might have to hold off on downpipes til more funds, but right now I just want it back together so I can ride it!

[masterofinsanity]

black wheels with white rim tapes looks cool mate!!

[arkell]

Spent the day polishing some more bits, doing some more cleaning and generally getting lots of bits back on the bike! 'Rear' of the bike pretty much sorted and wired up now, got some mini indies on the rear and a smaller plate. Look how obsurdly clean my undertray is mmmmm!! Also quick polish of the genny cover got it loking nice again. Been routing all the wires etc in according to the manual aswell just need some cable ties to fix em in place. Gotta get the rest sorted before friday as I have a week off work so can go play! Really happy with the difference ive made though as it looks much smarter these days

Anyway here's a couple of before and after shots!!

Before MINGING!!!

















After mmmmmmmm!







Still a few things to do and then fairings on and away we gooooooo!!!!!

[RedexRobB]

you've done a good job there, well done!

[mark400]

is that rear shock standard or upgrade? and the blue bolts around the engine casing.. are they from pro bolt?.. (and the oil cap)?..

No idea bout the shock, here's a pic, anyone know if this is standard or not?



Blue Bolts in my opinion look a bit shite, but cant really be arsed to remove them, but yeah oyu can get em from pro bolt (they were on the bike when I got it)

Oil cap slightly less tacky, but not my favourite, they come up on ebay from time to time, was on the bike when I bought it

I have the same shock, Its from FOX in the USA.

[arkell]

I have the same shock, Its from FOX in the USA.

Thanks for that!.....Is it meant to be any good? I havnt ridden any other zx4rs but mine seems rock solid!

[arkell]

Been doing some more stuff today

Got my stainless steel downpipes on courtesy of jack (jackdim), took off the radiator to make it easier, blew out a load of grime on the rad using compresser, flushed out all the old coolant in the system and filled up with fresh antifeeze/distilled water mix.

Unearthed my old mans torque wrench and went bonkers with the manual torquing stuff up the right amount!

Rigged up a bottle hanging from the ceiling to hold fuel and fired her up. running smoothly still did the last few things like adjusting clutch, brakes, lights etc

Cant seem to get my indies to work though...they all light up but dont flash and the relay makes a loud buzzing noise, is the relay fecked then?

reckon i'll have it on the road in a day or so well excited (except summers over doh!)

[jackdim]

Looks awesome mate

[RedexRobB]

Could be a broken relay, check all the terminals and make sure theres no corrosion.

[arkell]

Could be a broken relay, check all the terminals and make sure theres no corrosion.

Checked all the wires and sprayed some wd40 but to no avail, will get a new relay and try that.



Got front fairing and seat on bike today for a slow pootle up the road, everythign (except indies) working atm, got back after just bimpling up and down the lane a few times and noticed a very slight oil leak from the genny cover. I had the alternator done in april by C&B Mann (birmingham) so surely the gasket shouldnt have gone by now. Where do I stand in terms of parts/labour warranty before i ring them and rant!

Also the revs are hanging slightly at about 2k for a few seconds before dropping down. Im putting this down to not being ridden for the last 8 weeks and stale fuel or whatever?? Cant wait to take it out for a blast

Anyone got a spare indy relay and/or advice on my genny cover leak?

[RedexRobB]

If it was me id get the genny cover off myself and use some Hylomar blue on it. Did it to Lewis' bike and as far as i know hasnt leaked since i did it a year ago. You also have the added benefit of knowing you did it, and you did it properly.

See how you go with the revs hanging, as you know it can be the inlets leaking, are the carb clamps done up tightly?

[arkell]

If it was me id get the genny cover off myself and use some Hylomar blue on it. Did it to Lewis' bike and as far as i know hasnt leaked since i did it a year ago. You also have the added benefit of knowing you did it, and you did it properly.

Could you 'talk me through' what to expect when doing this? Do I need to drain the oil? Its due an oil/filter change so might as well do that same time if so.

Will I need a new gasket from cradley do you reckon?

cheers mate

[RedexRobB]

You do need to drain the oil if you do it with the bike upright. However, if you do what i did and lay the bike on its right hand side on an old tyre (panel off obviously), you dont need to drain the oil.

If your getting a new gasket then you wont need the hylomar sealant.

Using just the sealant to fix it, youll need to get the genny cover off, you can loosen it with a rubber mallet and a light tap. It is a pig to get off because of the magnet, but just needs a good tug. If the casing comes away clean without snagging the gasket, clean the the surface of the casing and that of the gasket with a clean rag. If it snags the gasket and tears, really youll need a new one. To apply the sealant, what i did was dab the tip of the tube on the gasket while squeezing the tube gently ,and work my way round to get a thin application, do the same on the casing sirface. If you can take the gasket off completely without ruining it, it might be worth putting a dap of sealant round the other side too.

You then put the case back on and press it back in place, dont do the bolts up just yet. Wait 10 mins for the sealant to cure and then tighten down with the bolts hand tight, then tighten properly in a diagonal pattern as to not warp the case

A piccie for what it all looks like