ZXR400/600

[zimm]

ok, so my 400/600 is actually starting to go back together.. thought i'd share some pics as the rebuild progresses..

frame is away being powdercoated, swingarm, wheels and a few odd and ends on their way from falloffslowly(?), and the engine is still in the back of my camper van in pieces, but hey .. its not like im working at the moment so progress should be swift once all the bits are here ..

to start with here's some old pics..

as i bought it


shortly after

note tacky anodised footpegs, badly polished frame/swingarm/wheels and the joke that was(is) an airbox ..

same battered panels, but black, (used them for tracking my 400) also sporting black wheels !


then i sprayed the same panels green, fitted some re-valved forks, EBC prolite race discs, replaced all the calipers, new wheel bearings, replaced shock linkage, MOT'd it.. and promptly blew the engine up




so here we are .. started cleaning up the forks and yokes, sanded out the casting marks and a quick polish up with some autosol











torque arm came up quite nice



sadly this is what the rest of the bike looks like at present



tomorrow its exhaust polishing and brake rebuilding !

then i just need a zx6r rev counter, an airbox, and to get my new swingarm and subframe blasted and powdercoated to match the frame..

[RedexRobB]

Mate i wish i was back doing mine up, it was so much fun! I really am considering matt blacking my zxr now....

But all looks good mate, im sure the finished article will be beautiful.

[masterofinsanity]

you're gonna regret all that polishing mate, believe me, looks good tho'

[zimm]

you're gonna regret all that polishing mate, believe me, looks good tho'

maybe, but that and the rearsets is it, frame/swingarm are being powdercoated.

[zimm]

Ive got my frame and wheels n stuff back from the powdercoaters .. !!

and what a fucking nightmare it has been just get some silver stuff made black (or in some cases a black thing made black going via silver).. i feel like ive been gang raped by the industrial estate mafia ..

no .. really, it hasnt been fun.
pics tomorrow..

big things i havent got at all, in any shape or form, rear shock and an airbox and clocks....damn, thats gonna eat £££'s

small things i havent got

wheel bearings
head bearings
swingarm bearings
spark plugs
HT leads
clipons
levers
tyres
correct (42th) rear sprocket

things i probably ought to spend ££ on or i'll regret it every time i look at it,

stainless fasteners
some carbon
some titanium

maxton shock
636 radial forks
6 pot/radial calipers
digital dash

[rene]

if you go for the 636 forks then you'll be using radial calipers id stick with the 636 wheel as well better disks and there lighter!

[zimm]

know what width the 636 rim would be there rene ? still take a 120/60/17 tyre ? hope so, or i'll have to squeeze a fatter rear in there and i cant be fooked with that. besides, ive just bought a mint set of wheels and had them stripped and powdercoated, so would quite like to umm, use them... although a lighter front wheel would be nice ..

[zimm]

oh, yeh, pic's belatedly ..









sorry bout the quality ..

wheels (gloss) look ace

frame/swinger/subframe are matt (satin) black

[masterofinsanity]

copycat

[zimm]

didnt polish me rims though

[masterofinsanity]

let you off then.

[RedexRobB]

Looking really nice Zimm! Again, this thread is reminding me when i was dong mine! Strip, powdercoat, put together with some extra nice bits!

[zimm]

an auspicious day indeed !

actually started sorting through the pile of parts in the garage that were once a bike..

dropped the swingarm off to have the bearings installed (i aint risking scratching it, and i know a guy with the correct pullers)

installed the new head bearings into the frame

bolted in the yokes and forks ..

my shopping list is growing too ..

clipons
disc bolts
brake/clutch levers

once it gets to the rolling chassis stage i may even consider putting the cylinder head back on the engine !

[rene]

sounds like its all coming togeather nicely!

Big fav but couldnt take some pics of the frame changes could you? Still planning on starting mine this winter, or summer if the weather continues likes this..

[zimm]

no prob's .. although my camera is utterly shite at closeup stuff, its liable to be a lot blurry.

having thought about it a bit (and having two of em in the garage to look at) I reckon it'd be a far easier job starting with an H frame as the top mounts just bolt to lugs on the frame spars anyway, so you could just make big brackets up, then the only fabrication is the two rear mounts... maybe the cross brace would get in the way ? dunno ..

its weird actually, when i went to pick my frame up from powdercoat there were a few others that had been done, and its not much smaller than the bigger bikes... so it's odd how it builds into something so much smaller.