www.zxrworld.co.uk

Hi All.

As promised in the newbie section a project thread for my new ZXR 400 H1 which I picked up today from Bristol. I left at 5.30 am and have just taken some pictures. I am pretty impressed to be honest.

After completing a full restoration on a Mini City, (pics below) I needed something else to spend my time doing!





The initial plan is to give it a complete service as well as new tyres and brake overhaul including a caliper rebuild and a carb rebuild. I will then use it as a track weapon for the summer.

Then I am going to complete a full rebuild on it including powdercoating the frame and wheels, painting the fairings, new seat fairing, something like a CBR 600 RR and an underseat exhaust, I also have a G model ninja rear suspension unit which will be going in.

Hope you like the pictures:










I am off to Turkey now for a week so progress to follow after that!!

Cheers

Jon

Quick update:

I have started to strip the bike down. The major work being removing the brake calipers which took a lot longer than expected due to pretty much every bolt being seized in place, some required drilling out. Pics to follow:








I also noticed the tank has had some filler in it at some point so going to need to replace this aswell.

Next is to get the wheels removed and painted and back on again to re fit the calipers.

I also tried to start the bike this morning. It was turning over fine with a new battery but not starting. With a bit of fiddling I found the fuel hose was disconnected, i connected this up and turned the fuel tap to on but it starting leaking from the front of the tap, think I need to change the seals, anyone any idea where to get these?

Thanks

Jon

Im sure you cant get the seals seperate from kawasaki, however a new genuine tap is less than 15 quid iirc.

I have done a bit more work on the bike this weekend.

Have completely refurbed the brakes which are ready to go back on. Couple of pics:




I have also bought a gsxr 600 rear seat fairing which is going to be going on and a spare set of H1 wheels with four good tyres for £5.50 which I'm well chuffed with.

Hopefully get a nose cone and front fender at some point, if anyone has this?

The plan is to cut the rear seat subframe back as shown in the picture below.



I also want to get a H2 swing arm and get rid of the torque bar making a bracket to mount the rear caliper on, so need a H2 swing arm as well.

Cheers

Jon

good idea with the h2 swingarm, lots lighter too. You will need the H2 rear wheel tho, or the h2 spindle and spacers, and the rear brake hanger i think.
I cut my subframe there, then cut off the rear section that sticks up, stuck that to the back of the new cutdown subframe. I get a good fixing with my rearend on that, and it also lifts the seat height up a bit.

when cutting it down tho, make sure you leave the mounting for your exhaust hanger!
good luck with it mate!

My seat unit in need of filler and paint but here goes:






Its a gsxr-600 rear seat, bought from ebay for 99p which i have cut and bonded to the front of my original seat fairing, looks good and the lines with the bike look really good.

I have also bought a pair of H2 wheels with 2 sets of tyres from ebay for £5.50, an absolute bargain.

I need to find a H2 swing arm now, seems to be proving difficult.

Let me know your thoughts.

Cheers

Jon

looking forward to seeing that seat unit evolve!!

hey mate got a spare nosecone heew with soem damage (snaped off above the mirror ) but im sure you could fix it lookign at ut handt work ill get some pictures

Seat is almost finished now, filler is on and need a last layer of bondo to smooth it out.

My fuel tank just arrived in the post so will fire the bike up this weekend and if it runs fine i will completely strip it down to get everything powdercoated.

Few pics of the seat.







Cheers

Jon

that is bloody impressive!! well done.

Hi

Thought i'd best crack on a bit as Im going away for a week on saturday so here it is, got home tonight from work and pretty much stipped the bike.

Couple bits to do but everything is almost ready for powdercoating now.

Heres some pictures:






List of jobs to do, buy and test fit swing arm, finish seat, buy fairing and front fender, modify subframe to fit zx6r shock.

Cheers

Jon

Hi

Not much updates recently but have picked up the painted frame, swing arm and seat subframe from the powder coaters and they look brilliant.

I have started to put some bits back together but still have a lot of painting to do.

The wheels and yokes are being powdercoated as we speak.

As i couldnt find a H2 swingarm i am just using the H1 one that I had.

Cheers

Jon

Looks good, cant wait to see more progress, good job!

Bit more progress today:

I took pretty much every metal part to work, washed them in the parafin tank and shot blasted them.

Everything cleaned up really nice so I hung it up and gave everything a fresh coat of paint.

Let me know what you think!!










Cheers

Jon

Hi

Have now mounted rearsets and read shock, need ot make up a spacer to mount the shock in the right place, then I can remove it to fit the swingarm - just need some new bearing for that.

Let me know what you think






Thanks

Jon