Danman's ZXR 400 L9 build (day by day)

[Danman109]

So hey guys, this is where im going to post the progress on my zxr400 as at the moment all of the bike is stock with the original parts.

The Plan:

1) bring the braking system up to date ( the old lines visibly expand when pulling the lever ) so new braided lines are to go on, HEL or Goodridge. (front and back) possibly a 6 pot caliper conversion which looks tasty!

2) De-restrict - i suspect it has restrictors on the carbs only but who knows

3) Wing mirror indicator project - LED 'Ducati style' along with flush mount indicators rather than leave empty holes in the fairings, also adds visibility so im happy with that.
4) New exhaust downpipes - the old system has gone all holy, sounds fantastic but annoys the hell out of the neighbours (ideally i want to go with a stainless steel system however i feel this is slightly out of budget reach right now.. we'll see) the bike may need dyno-jetting too as it runs slightly rich at the moment.

5) Suspension - re-condition and set up by MCT for my weight and riding

6) K-conversion fairing kit - a Road/Track fairing kit to be ordered in metallic blue and the wheels to be re-sprayed gold, with a ram air box and the frame to be sprayed black.

For now here are some pics of the bikes old and new









---- EDIT 1/3/11 ----

Calipers stripped and cleaned... THOROUGHLY (it needed it badly) i now have all 8 brake pistons working (rather than 3 between both calipers)

---- EDIT 3/3/11 ----

Goodridge brake lines - ordered
Caliper piston seals - ordered
Full service (inc. filters, plugs, oil, + fitting lines + seals fitted) - booked in for 15days time

---- EDIT 9/3/11 ----

Goodridge lines - arrived (wrong ones sent back and re-ordered)
Caliper piston seals - arrived (to be fitted)
Full service to be done next week ahead of schedule (restriction washers to be removed during inspection of carbs)

---- NEEDED ----(please shout if you have any of these items spare! much appreciated)

Rear hugger without holes please!

Rear brake Disk in spanking condition please (it needs to last, i dont want to have to replace it, if that means buying new then thats fine too, please shout with your best price )

Stainless exhaust downpipes (im keen to keep my MTC end can but not too fussy)

Rear shock, no rust, good price, as i am considering upgrading anyway.. we'll see...

[Mori Man]

Rear shock looks bad - almost reminds me of my bike when I got it 1st

Doesn't take long to get them looking tip top again
MM!

[Danman109]

Rear shock looks bad - almost reminds me of my bike when I got it 1st

Doesn't take long to get them looking tip top again
MM!

I reckon it's largely to do with the holey rear hugger which seems completely useless if you ask me, do you reckon it's worth upgrading the rear shock or getting that one re-conditioned? Many thanks! Dan

[Mori Man]

Does seem strange they put the holey moley hugger on some of them

If you have the dosh then always worth upgrading the shock , but a refreshed original is going to give good service for a few years.

MM!

[bendog66]

I have a non holey rear hugger. All lugs etc intact. PM me if you're interested or want pictures

[Danman109]

Wow so it's been a while and i figured its time to update this thread,

So far the mods are:

Carbon Fibre front mudguard:


Stainless downpipes:


Flushmount indicators:


Removed mirrors and blanking plates from other side of intake tubes:


I have replaced my old rusty shock for a shining spanking new(er) one and it performs SO much better i'm SO glad i did it! (no picture as yet but i'll put it in an edit)

The project for this weeked is replacing the rocker cover gasket.. soon a Chain and sprocket kit will be required (gearing for more accel?) and i will be getting the carbs set up for power on the Dyno (a mere 62.4bhp at the moment)