ZXR400-L (1992) Rebuild

[SammyG]

Hi guys, Quick introduction first; I've been looking at the site for a while, only recently joined up. I've had my ZXR400-L for just over a year now, awesome bikes!
Sadly now I live and work abroad, but rather not sell it, so decided I'm going to turn it in to a project.
*After stripping the bike down yesterday, I have decided to keep the zxr400's engine in, but it needs work! Head gasket has blown, and it just doesn't sound healthy*
I am thinking about re-spraying the frame Gunmetal Grey, and getting white fairings, but I want a new tail end, has anyone changed there back end for that of another bike? I fancy something similar to the R6.
(Pics to follow)
Sam

[SammyG]

And the day begins....

Fairings off... Not much more to go....

And we leave it there for another day...


Dropping the engine out today hopefully, if the weather holds out!! And then the slow process of rebuilding!

[SammyG]

Another day, and still more to go!



Doesn't seem as fast as it used to be


Back to metal for the respray


Getting there, gradually, I am just dreading the rebuild!! I'm looking at parts wondering where the hell they came from!!!!
What brakes do alot of you use? I have heard the zx6r calipers fit straight on, any particular year model? The brakes never really felt to great when they were standard.

[RedexRobB]

ZX6R brakes wont fit. Youll need K1/K2 GSXR600 4 pot calipers, or some Honda calipers not sure on year/model but i know theres some grinding work to do to get the disk all the way in the caliper so it doesnt rub.

Shoulda taken pics of everything, believe you mean it comes in handy! And bagging/boxing things up is a good helper too. Guess youll have to assemble all from memory!!

[SammyG]

Oh- I read somewhere they just bolted straight on! Cheers for the other ideas though shouldn't be hard to source the parts really!!
And yeah, I guess I will!! that might be fun... My mate who is helping used to be a mechanic, and thinks he knows where everything goes.......... Proof is in the pudding I reckon!!

[SammyG]

Parts almost ready for respray
Tank

Swingarm

Primed ready for spray


Sprayed, needs a few more layers and lacquer, but not bad


I don't seem to be the fastest at this paint stripping business, but I am getting there!!