USD Conversion on my 400

[Mori Man]

Some of you might already know that I have a ZRX400 & not a ZXR400

However, I am installing a ZXR400H1 front end and a set of wheels on it too

I will add photos to this thread as soon as I am able - have been cataloging my progress

As of today it is full steam ahead on the swop over and I hope to do my first road report on Saturday.

Lots more to come

[masterofinsanity]

look forward to seeing pics and don't worry bout it not being a zxr400 neither is mine

[masterofinsanity]

oops i split the wrong post naughty me.

1st piccy's

Photo's supplied by seller




My own shot's

[Mori Man]

Suddenly the conversion has come on leaps and bounds - the main reason was my own calipers fitted the USD's which has saved me a lot of work overhauling the original 4pot Tokico's.

I also had my local shop do the overhaul on the forks to save on time/energy too!

Decided to clean and semi-polish the bottom clamp, also removed the casting marks










This was done using a Nylon sanding pad on my angle grinder, but be careful as this was a milisecond touch on my knuckle!

[Mori Man]

Next the top clamp got the treatment;







After that I started to polish up the bottom clamp;

[RedexRobB]

wow thats some good work you done there mate! keep it up!

[Mori Man]

Next on the list was the wheels, shame the colour was wrong for my bike as they cleaned up really well




I chose a Kawasaki Green Black Pearlescent;





After the top coat has been applied;

[Mori Man]

Now it was time to prep the front muddy to spray it the fastest colour

But it needed some small repairs done before the final primer and top coat goes on;




Got my soldering iron out;



...and done this;








These were just hairline cracks but if you need to repair scars,gouges or chip's then your local modelling (That'll be Airfix ) shop will supply you with plastic rods in various colours.

A sand with 800 grit wet & dry and some kniffing putty soon smoothed it all out

[Mori Man]

Nothing complicated here, I bought myself a bike jack for beer money and it works a treat Rated to 500Kgs and very secure.

No siezed parts, but I have had the Bikini off before

[Mori Man]

Things are going well so decide to locate the bottom clamp;



I gave the bearings a fresh grease up! , and installed new seal's top and bottom;



After that it was back on with the bars;




Wanted to see how the Bikini was going to line up with everything;



.... and I picked up my forks around 6.30pm so had time to slide them in too see how they looked too



(That was yesterday)

[masterofinsanity]

looking good mate, keep the pics coming.

[Mori Man]

Start of rainy season today so was up and out early before it started to piss down

The front wheel got a new tyre fitted on it on Monday so it was sitting ready to go on;



I went round and checked all my fixings for secureness and placed the ignition barrel under the seat. No clocks fitted just now - all will be revealed later! As you can see the muddy also went on in it's primer coat to allow me to have a run before the rain commenced;





This is a rough build just now to get that 1st road test in and iron out the bugs over the next 4 weeks of rain. Come end July I should have nearly all other parts in place to finish but I will have cured all the little niggles like the "lock to lock" is too small and I need to do a 20 point turn!! Locate the ignition barrel for more practical use.

The performance already is stunning and I can't wait to start dialling in the suspension to bring out the best in it
Rear wheel will need to wait until my existing tyre is a bit more worn as it is only 3 weeks old.


What it might look like nearer the end;

[masterofinsanity]

very nice again, wouldn't mind a zrx myself but think i'd go for the 1200

[gubbs]

Looks amazing! Very nice bike indeed.

I have a few questions:

Nylon polishing pad to bring up the ally 'semi polished' looks great, much better than a full polish imho.

Was that all you did? Nylon pad? No other prep or treatment?

Also re: the paint you used on the wheels, was that rattle can or compressor job? What process did you follow? Prep with fine paper, prime, colour coats then t-cut it? Or just clear coat?

[rene]

that looks lovely, makes you feel warm and fuzzy to no that poeple still care about older bikes!

excerlent work