ZXR400?

[arkell]

this will be the best H model out there imho, cant wait for finished product!

[Mori Man]

this will be the best H model out there imho, cant wait for finished product!

Long way off that yet ! But thanks for the comment

Been raining past couple of days so no chance to get the front and rear end done

However it's meant things which were just going to be rattled back on have been getting washed, polished , primed and painted.

The loom even got a wash , some repairs and a wax!

Never realised the subframe was aluminium alloy or I would have done some polishing on it along with the frame - doh! Ah well a wee winter day's project

Going for the SP build 1st and that will give me time to get the peg hangers and bungee hooks painted.

Next few day's are forecast rain so looks like I'm going to bite the bullet tomorrow and get wet, need to get this up an running for the weekend so I can book it for it's MOT next week.

I'll clear out the bike shed and throw a tarp' over the neighbours push bikes and get both bikes mostly covered. Wont be much in the way of photo progression maybe a pic at the end of the day.

Here's how it sit's just now - got some tidying up to do but generally it's looking OK


A comparison of the two tail unit's;


Ooooooo , zorst just arrived

[Mori Man]

Well it didn't rain ! Indeed it was a pretty warm sunny day after mid-day

So two front end off and two front ends back on again with the spare set of H USD's ready for overhauling (In the distant future lol).

Once the ZRX was road worthy again (need it for tomorrow and the weekend) it was time to crack on with the ZXR.

Front end went on lovely , done a bit of work on the callipers and finished off with putting the front end cradles on, sighting the loom, new levers, front cowl and carbon huger but will remove again but wanted to see the look with the carbon inserts

Amazing how a few bits can transform the build and tomorrow I should have the back end complete then it's on with all those fixtures and plugging in the electrics. Predicting Sunday for exhaust on and 1st fire up, this weekend is actually chock a block but have to get this running Sunday !

Saturday 4pm We are off to one of Japan's largest firework displays - it's actually a competition and lasts 2 n half hours around 800,000 spectators so loads of totty in summer kimono's ( Yukata's) Then Sunday is MotoGP but the sun will be down by the time that starts.

Tomorrow I need to head of 11.45am to go put our sitting sheet down for watching the display - generally go for the same spot each year as the view of the 12" shells is spectacular

Here's today's progress:








MM!

[Mori Man]

Saturday - Got the back end all buttoned up and the bike became a working rolling chassis

Sunday - Pretty damn tired after the fireworks display , to avoid the traffic jam's I would get off the bike and just push it along the pavements - fed's are cool about you doing this here and indeed at a few junctions that I drove up to between cars they came over and said if i pushed the bike i could get up to the next set of lights using the pavement Of course fuelled with adrenalin it seemed a doddle to push it up a half dozen streets - next morning didn't feel so fit, Doh! Next , JSports was doing a catch up on Superbikes from 3pm ending with the race live and of course MotoGP was on too So Sunday was a non starter on the ZXR

Today - Raining but cleared out bike shed and dragged the bike centre to work on. Got everything that needed bolted on or plugged in to get the engine running, put the battery in and turned the key - instantly I could see there wasn't enough juice in it, bugger ! Did have it on charge for a while but needed to be an overnight job (tonight). So pulled the one out of the ZRX and switched on again, idiot lights nice and bright so hit the button and nothing ! test horn , no prob's , test lights - they come on, press the button - nothing mmmmmmm when I was cleaning up the switchgear I thought the internals looked a bit dicky so went into flat and pulled another out of a box. Plugged it in and a slight murmur but still not healthy OK give the solenoid a tap and hey presto good healthy turns

Now time to get some fuel into the game , I've a small container for filling chainsaws so I just put the fuel pipe directly into it and hit the starter again - after about 15 revolutions nothing was happening so thought I would help buy pouring a bit of fuel directly into the ports. Hit the button and some splutters but not really catching - by this time I'm noticing that the containers fuel level isn't dropping so as I'm spinning the engine I'm watching and it definitely isn't sucking up fuel Did I swap the fuel hoses round on the pump? Ok, swap them and see what happens - loads of bubbles coming up so it's certainly the feed pipe so swap back to original set-up but still nothing.

Not one for messing about i popped back into the flat and pulled another pump out of a box and got the fuel lines onto it and plugged it in. This time I used my trusty jam jar full of fuel and put the hose in - within a few turns it was already half empty and at just about empty the bike started to catch Swap back to container and a bit of choke and vroom the engine kicked into life again

Still sounds sweet as a nut and still no clutch rattle - makes no odds if I pull in the clutch. Let it get up to temp then switched off, re-started and gave it a blips , let it sit for a while cooling down and got on with other stuff. Checked all the fluid levels and everything is sound so started it up again

To do:

Indicators
Switchgear and throttle cables
Rearset for brake
Headlight bulb replace
pilot bulb replace
Bolt on plastics
Put fuel in the tank
Balance carb's

...... and that should be it ready for it's MOT.

crap weather so no chance to get a photo done , next couple of day's are meant to be rain too better be nice by the weekend though :smt013

MM!

[masterofinsanity]

why is it everything you do looks sooooooooooooo goddamn clean???

[Mori Man]

It's the lighting that makes it look that way

Pissin rain for next few days as a Typhoon is coming but Sunshine is forecast for Saturday !
http://tenki.jp/forecast/point-442.html

[Mori Man]

Well it stopped raining for about an hour so pushed both bikes out and took some photos

Nearly done now - can't belive it's coming to an end , well for just now

While it was still raining:





Out in daylight - still no sun though

[Mori Man]

Rain, rain and even more rain !

But still managed to make my way through the "to do" list. Indicators are sorted enough for now but later I will make some better mounting plates for them with a rubber mount insert as not keen leaving them directly bolted onto the plastic

Throttle cables are on - the SP ones I have are too short So going to check their numbers to make sure that they are M cables So have got some GPz9 cables on (luckily had in cupboard) but they are way too long so have had to bring them in front of idiot lights and feed back under headstock before going under the frame. If the SP cables check out to be actual M cables then I'll get some custom made ones done with braided sleeves

Swapped out the switchgear and all is well except the front brake light switch so will run a couple of patch wires directly down to the block connector for just now and tackle the fix at a later date.

Bought some new hoses for the oil catch tank and a nice square section of Velcro so that will get sited tomorrow. apart from the front brake switch all electrics are working.

A couple of grommets to put into front screen and change all fixings to stainless and that should be it

A few fasteners seem to do nothing so will photo at weekend and get your opinion on them The lowers also have a mounting hole that's not being used so assume something on the J2 exists there

The single seat cowl or something is not allowing the seat to fully come down and fouls on the battery - I know this was fine before the strip with the dual seat panels on However, I fitted the ZRX battery back in for just now and everything buttoned up fine so may consider buying one of these as it sits on top of the battery box which would be a handy space for something !

Not missing an opportunity I fired it up again and let it get up to running temp' , switched off then started again , a few blips and that was it for the day.

[Mori Man]

Just noticed in this vid' that you can see at the very start one of the fixings - it's normally a Black button head Philips that goes into the engine mount cradle on both sides.

I have now replaced them with Stainless , my only guess is they hold cables straps otherwise no idea ! Anyone ?

The other two are on the generator casing and clutch casing - again button heads and since nothing lines up with them wonder if these are again for cable straps - Those rubber coated metal strip type.

[WelshD1K]

im gonna hunt you down and kill you for your zxr!! haha

howcome the zrx is on standard forks again ?

[Mori Man]

im gonna hunt you down and kill you for your zxr!! haha

howcome the zrx is on standard forks again ?

One of the bikes is destined for a ZX636 front end but needs to wait until my wallet recovers So the ZXR got the J2 forks to get it MOT'd

So, until then the ZRX get's it wibbly wobbly stumps back on - although I'm very tempted to overhaul the H2's USD's as the standard legs really do feel awful now

Monster Typhoon passing through today and they've just announced a Hurricane warning in our area

http://www.nhk.or.jp/daily/english/08_08.html

Note, it's moving at 55Km/h but wind speeds are 144Km/h - now where did i put my kite

[Mori Man]

Well today was my 1st official ride on the bike Or indeed any ZXR400

Wasn't far just up the street - no helmet and reg plate but what the 'ell

1st impression , what a silky smooth box ! I've never known a Kwak not to knock into gear but nothing The clutch is also uber light , I initially was expecting it to clunk into gear and stall so had the front brake well on. No problem though, about a mm of play and that was it away - going to have to get used to that or adjust for a bit more but with the gears engaging so nice i don't want to disturb.

Bike is very well balanced and feels much lighter than the ZRX - manoeuvring it about is a doddle, seat height is a bit taller as I am more up on my tip toes than the ZRX.

Looking forward to my 1st road ride

Today's snagging list:

Front brake light switch - thankfully i have the one off the ZRX so will swap that over tomorrow.
Fuel tap - looked in great condition and pissed out fuel from every fuggin crack ! have various taps in the house so raided a new one for the ZRX for the O rings etc - still weeping so fit the scabby original selector with the new O ring and wave washer and that's cured it for now. a new fuel tap is in order.

making the plates for the front indicators and really that's it .

[Mori Man]

That's the front brake light switch swapped and working fine (popped out with the torch and hooked it up )

Here's what I'm making for the front indy's - those standard holes are fuggin huge ! Still not finsished

per side:
3mm Acrylic sheet spacer x 2
3mm Rubber damper x 2

Cut , file and drill to shape / fit



Looking like Monday is MOT day

[RedexRobB]

looking very very good! Good luck with the MOT, im sure it will fly ythrough!

[Mori Man]

All legalised now

Realised that I never listed what was changed , renewed, repaired and the likes.

New Parts fitted:
Screen trim
Replica mirrors
Handle bars
Gel Grips
Clutch cable
Front Pads
Rear Pads
Chain
Chain slider
Plugs
O rings on spark plug well top and bottom
rocker cover gasket
coolant
Carbon filler and tank pad
Top Yolk carbon protector
Fuel tap
Crankcase breather filter
Assorted OEM bolts & Stainless fixings

The rest
Screen replaced
Clocks replaced
BEET limiter off
Cowl
Lowers
Side panel/seat unit
FCR carb's
SP forks
SP shock
BEET rearsets
BEET Titanium exhaust
Right Switchgear replaced
Front brake light switch replaced

Painted & Polished
Frame & Swinger Polished and painted
Triple clamps painted
Torque rod
Assorted brackets painted