My First Kwack build - To do List

Here's a chance to show off your zxr400, so get them digital cameras out and show us some piccies.Rebuilding your bike or modding it then let everyone in on it.

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Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Old oil had collected at the bottom, no metal bits or anything untoward in the filter or sump bottom.
gear selectorL.jpg
gearboxz.jpg
Not too shabby for a bike 25 years old!
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

So, ever wondered how much grease is in your fresh out of the packet bearings???
open bearingw.jpg
and why they don't last too long. Top tip is to prize off the rubber seal with a stanley blade and pack with marine grease (lithium based)
greased bearings.jpg
I got 25 years or crap off the bolts and the dreaded Kwak red threadlock. But in the past my wire brushed bolts have gone rusty due to being a bit enthusiastic on the bench grinder! Another top tip is to put the bolts into card and clear lacquer them...Hey Presto! :excited
lacquered bolts.jpg
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

All of these little bits mean that the wheels are finished....Yay!
finished front wheelv.jpg
finished rear wheel.jpg
Although I may have to admit defeat with the Rear shock adjuster. The selector knob had to be drilled off and the screw is not for turning, hmm.....
shock adjuster clean.jpg
Still on the to do list:
Strip, prime and paint all the ancillary bits, pegs, hangers, brackets, clamps etc.
Grease swingarm and bearings and fit steering bearings.
Get the engine sorted and put into its frame
Finally polish the frame, keep putting this off, so I can start with the big stuff and get a rolling chassis.

Think that will do for now. Any hints tips or comments, please add :smt006
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
JamieNeve
Posts: 197
Joined: Fri Jan 25, 2013 12:33 pm
My Bike: CBR600RR, ZXR400 L-2
Location: Waterlooville, Hampshire

My First Kwack build - To do List

Post by JamieNeve »

Those wheels are looking great!
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Mostly I have spent the week wire brushing crap off rusty parts and priming. So many bits, next time, powdercoat!
primed bits.jpg
Shock now fettled
naked shock.jpg
and complete!
complete shocks.jpg
Engine is back, painting that too seeing as it is out. Frame needs one last polish to be spot on, then time to put it back together. Considering powdercoating the sub frame as I really cant be arsed with all the faff!
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Guess what, more bits to prime, off the engine this time.
engine bits.jpg
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Painting is nearly done, my efforts this week include,
cleaned engine.jpg
wire brushed and cleaned

Hammerite smooth black for the casing covers, great finish.
painted covers.jpg
all the other bits! Spot the odd one out, bonus points if you can name the bike lol
painted bits.jpg
You do not have the required permissions to view the files attached to this post.
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

And now the engine..... :excited
painted engine.jpg
Knackered bearing out of the swingarm (remember the circlip next time before twatting it wit a hammer and drift!) and put back together...
rear suspension.jpg
and where we are up to now
frame swingarm and shock.jpg
waiting on engine casing gaskets and then we can start building properly. Think a full paint job will have to be sorted, new fairings off fleabay for £20, get in!
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Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
User avatar
Dominik
Posts: 110
Joined: Tue Oct 07, 2014 11:05 am
My Bike: Zxr 400 L3
Location: Trier - Germany

Re: My First Kwack build - To do List

Post by Dominik »

Looks great!
Which colour have you used for the engine?
Zxr 400 SL - 130kg
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

I used hammerite smooth rattle can from Halfrauds for a tenner, silver for the engine, black for the casings. Astonished at the results, really good to be honest. Tip from and old engineer who does rebores, cranks, etc.
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Work and money have got in the way last few weeks. Finally have the engine in,
engine in frame.jpg
As of yesterday,
half done bike.jpg
and onto the rest of the bits!
You do not have the required permissions to view the files attached to this post.
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Plonk
Posts: 46
Joined: Sat Jan 10, 2015 3:40 pm
My Bike: GSXR 750 K3
Location: Peak District, Edge o't moors.

Re: My First Kwack build - To do List

Post by Plonk »

Rear lamp next,
old rear lamp.jpg
Seized and knackered! Bit of fibreglassing...
repaired rear lamp.jpg
All sprayed and on the bike, pics to follow. Braided hoses to be ordered next week, give the wiring loom a going over, find out why it isn't firing on number 3 and fill it with new fluids, plugs, filters etc! :roll:
You do not have the required permissions to view the files attached to this post.
Rides better in my head than on the roads...
Fettled GSXR 750 in stealth black.
Cagiva Mito Mk II
Cagiva Mito Mk II Eddie Lawson Rep
ZXR400 H1 Restoration project
Top-shaggy
zxr400 oc member
zxr400 oc member
Posts: 128
Joined: Sat Aug 30, 2014 12:03 am
My Bike: KR-1R
Location: NE Derbyshire

Re: My First Kwack build - To do List

Post by Top-shaggy »

Looks like it's coming on a treat. Great pictures, please keep us updated :)
We are we're we are..
Leey
Posts: 138
Joined: Sun Apr 17, 2011 11:23 am
My Bike: Zxr400L8
Location: gloucestershire

Re: My First Kwack build - To do List

Post by Leey »

As above looks like this project is coming on great :smt001
JamieNeve
Posts: 197
Joined: Fri Jan 25, 2013 12:33 pm
My Bike: CBR600RR, ZXR400 L-2
Location: Waterlooville, Hampshire

My First Kwack build - To do List

Post by JamieNeve »

That rolling chassis with engine looks beautiful... Keep us updated!!
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