www.zxrworld.co.uk

Harry, absolutely superb

Very lucky to have a workshop like that

A couple of things,

You didn't appear to have the barrells/head on when you had the cardboard airbox mould fitted ?? does it all line up??

The ramair intake, you don't show where it is!, don't use the original tubes, unless you modify the fairing to have the intake right at the front, otherwise air just flows over the original intakes and won't give you any ramair effect, due to the shape of the fairing

If you get it right, you may find a market for ZXR400H ramair boxes, as there aren't any being made anywhere as far as I'm aware, a nice lttle earner

And finally, as others have said, your english is far better than some english people, don't appologise

Best of luck with the project, keep us updated

Greville

i thought actually use the tank 'as' the airbox lid, and fit the bottom section to sit nice against the tank, using the foam edge to seal against the tank. Im sure you could get a good enough seal this way, it just might take a bit of time to get the shape right.
It would be a great help at the track, cos you just take your tank off, and you are on the carbs..would be good.

you know that sealing strip you put around doors to stop the drafts and cold etc.. that might do it maybee? you could stick that to the underneith of the tank, and to the top profile of the airbox bottom..

Jake, that's how BDK do it on their zxr airboxes

You do need to weld in sections to meet/seal with the lower half of the box though

Thank you for your help mate,

When i made the bottom ram air mold, ive put the engine on and measured it so i think thatd be ok.
The ram air intake is still a concern as im willing to keep the standard front fairing on, i would probably make like a big air scoop from the headlights cut-out runs down the bottom yoke and straight up to the bottom of ram air. Or run it through the original tube which will be modified and get connected directly to the ram air from the lid. Im still not sure, but your advice really made up my mind, that really helpfull.
I think im going for first plan, running from the headlights cut-out, but im not sure as i only have 2 months left to finish my project and go for my big presentation in june.

Cool

If you going under the yokes, you don't need to go to the front of the fairing, you can just have a 'scoop' above the radiator, ie between the raditor and the bottom yoke, It's how Kawasaki did their 'kit' airbox

You won't have to mess with the fairing at all then !

cracking thread mate keep it going, don't forget the race manual on the main website, might be stuff in there to help you, there is a race wiring loom here

Here's an example of the 'kit' airbox and scoop that goes below the yoke, it may speed up your project if you don't have the time to build an intake from the front of the fairing:

dont you need to mod the rad for that tho? Or just mount it lower?

RedexRobB wrote:dont you need to mod the rad for that tho? Or just mount it lower?

I don't know on the 400 H, looking at the rad on a ZXR750H it looks as if you can just drop the rad. I have seen people attempt to drop the rad on the L and sqeeze the top rows of the rad down, but there is a clearance problem with the fairing doing that. Ideally you do need to cut the rad on the L though.

aye, like Ballsout says, there is not enough room in the fairing to drop the rad/oil cooler.the H is similar to the L in that you will have to cut a section out of the rad. Its no big deal tho, just hacksaw the profile out, and crimp or solder the open ends shut

Also with the L, if you drop the rad, one of the fairing mounts that also doubles up for the radiator moves. Not sure about the H model tho.

Cheers ballsout for the pictures,
That will save me a lot of time by making that kind of ram air...

Mmmm...
I think on the H model, the radiator is a lot smaller than the L model which means the gap between the rad and the oil cooler is quiet a lot.
What im planning to do is to lower down the radiator mounts, get it closer to the oil cooler and that will leave big gap above the radiator.
But i havent thought about the fairing mounts....
I think the mounts is bolted to the frame on H, but im not really sure, ill double check....

On the L model theres a bracket near the bottom of the motor that attach to the bottom of the radiator and on top of the oil cooler, you can see it behind the clutch cable in the pic that ive attached, the fairing mount is also part of it, you can see where ive got a bolt screwed in for the fairing. Im not 100% certain if the H model has that or not for the reason you mentioned that they are smaller on some H models. But thats what im talking about anyhow. Obviously if you move that the fairing mount moves with it.

crapppp im stuck on the calipers now...
ive got PFM brake discs which are for L model....
i thought by changing the calipers with the L model ones will sort the problem, but it didn't...
Any suggestions guys?
cheers.

Whats the problem with them exactly?