Kawasaki ZX6D - ZZR600D build thread

UPDADE

THIS IS HOW IT LOOKS LIKE ON MAY 2014

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/s_6d3N0ZBY6rJKVjkvQ9ddTvPqQjTOC65fTS51PxgZ0?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-uvU9Huwi7mg/U3kIfVnY1_I/AAAAAAAADEQ/MFpUz3auIoE/s800/ivek.jpg" height="800" width="600" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/ZzrSlaganjeMolvice?authuser=0&feat=embedwebsite">zzr slaganje molvice</a></td></tr></table>







Hi folks, bought a beatten up 21 year old kawasaki sport/touring bike that has been streetfightered really badly and really ugly, so my plan is to take it all apart, and do a complete overhaul of the bike, some parts of the engine, and build a completely custom bodywork and electrics scheme, and turn it into a trueblooded sport touring bike.

I am doing all of the work by myself, with no help, and I don't own a garage, so I am doing all of the work outside, on the "terrace" in my back garden of the house that is around 100 years old, there is 10% slope so I am leveling it with some bricks and old wooden planks. I will ad a few tips on some stuff, you can basically do all of the work alone, you just need to think outside of the box

I allready dissasembled the whole thing, there are a lot of pictures of the process, so you are welcome to watch a lot of stupid pictures of an old and rusty bike xoming into a life again




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I will be updating this thread constantly, I plan to finish my work until 21.3.2012, start of the spring, so I have a lot of free time, but not really a big budget, so I will produce most of the stuff fon my own.

cheers,

a.

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A night fell, I realised I still have the energy to take the frame from the engine. Well, here is a tip for any garden mechanic as I am on how to dissasemble the frame and the motor. Every single manual says that you should have at least 3 people, engine hoist, a lift and I don't know what not. Simple logic is: engine is around 60-70 kilograms, the frame is 13 kilograms Simply lower the engine on the ground, undo 6 bolts holding the frame, and lift the frame with one hand or with two, if you are a girl ;-) It is a 5 minute process, so I really don't se what all the fuss is about.

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Here is the engine sitting on the improvised stand of bricks and plywood. The frame, the wheels, the forks, are all getting reassembeled, and are going to get a nice sanding, and then I am going to powdercoat them in a nice MAT BLACK colour, as it should be

I have to change stator cover on the left side, I have to adjust the valves, clean out the carbs, replace few nuts and bolts, redo the radiators and electrics, and get some new valve cover seals and couple of other tiny bits on the engine. I have to redo the exhaust, intake, and then assemble the bare structure together. After that I am going to start to custom wire the thing, because a lot of factory wires are bust, and connectors don't seem too reliable to me, and there is a nice way to bypass some switches, few less things that can go wrong. I just hope it doesn't snow in the near future because it will stop my progress.

to be continued...

a.

or rain. looks like a good start, i would cover everything with a tarp or something.

There is a small balcony right above the bike, so I hope that it is going to protect it from the elements. I have a 50 square meters spare space in the first floor, but I can' really put the bike in the house because I would have to kick some walls to put it back out once it is reassembled old architecture, tight corners...

+1

nice shots, is that a huge hole in the frame brace?

Yes, there are holes on both sides of the braces, but they are factory made. They really look ugly, but while I am et the sanding process, i am going to round the edges a bit, because I might put some wires through them in the future, once I decide how the bodywork would fit in.

There is going to be hundreds of pictures here in the future, I like to document my work so I know where the bolts go in case I forget Wiring loom is pretty much straight forward, idiot proof, every conector has ots own shape, so there is not going to be any problems on assembly, and I might cut it all out in the end

Having done similar things on a smaller scale, it might be an idea to put a tarp down under the bike, it's easier to find nuts & bolts when they drop onto a high contrast surface than when trying to find them under the piece of grass or slightly buried in dirt the same colour as they are.

It looks like a great project though, I'm looking forward to watching your progress.

I think that I am going to build a wooden deck in a few weeks when I start to reassemble the bike, just to level the things out . I managed to lose one nut in the grass, but I have a couple of really strong neodimium magnets from some old hard drives, so I just take one swoosh and it colects all of the metal bits from the grass. It is amazing how many bicycle nuts I found in the last couple of days in the gras with my magnet

I started to untangle the wiring loom, there are few wires that have scraped insulation, so I am going to recheck it all, to try too lose all of the unwanted resistance in the electrical circuts, to try to "blueprint" the loom as close to ideal values. It is a sloow and boring process, but it puts me in some kind of a "zen mod"

A "street-fighter" came with GIVI bracketry?

Cool project. I had been toying with getting an old 6E or ZZR and tarting it up for ST duty.

Have fun.

Well. it wasn't really a streetfighter, rather a really sloppy repair after the crash boy racer I added the Givi luggage this sumer, it is from my old" Versys, I had to mock it up because I am going to make all of the body work on my own from carbon fiber and fibrerglass, so I needed to check the clearances between the luggage cariers and the body work. I will have to relocate the water owerflow bowl to the front of the bike because I want to have the rear as slim as possible. The Givi luggage alone cost as 3 of these motorcycles put together

I strongly recomend you to get an old zzr, the older the better, because they are such a joy to work on. I got borred with the new motorcycles such as Versys, they really work fantastic, and have literaly no errors, but my engeenering nature drives me to dissasemble everything and redo it on my own, so I wanted really beaten up bike that I can build from ground up based on my own specifications

Bloody hyperactivity, it drives my girl nuts, whole house filled with old engines, car parts, bicycles, lights, even lego technic

Well, as it seems, we had a pretty mild winter, but as soon as I start to dissasemble my bike the shit storm comes and it seems that there is going to be a lot of snow for the next couple of weeks, so I am going to do all of the stuff that I can do inside.


I started to go through the wiring loom, all hundred meeters of it or something like that, and it is in a pretty good condition, except some loose conectors and scraped wires.

Here is a wiring in my warm kitchen, I have to source some new conectors for the new headlight, rear light, blinkers and such. I also need a new ignition sistem, the current lock and the keys are all fooked up, so it is going to be a pita to source all of the parts

<table style="width:auto;"><tbody><tr><td></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od 27. sije&#269;nja 2012.</td></tr></tbody></table>

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<table style="width:auto;"><tbody><tr><td></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od 27. sije&#269;nja 2012.</td></tr></tbody></table>

I started sourcing cheap parts that I can implement in the bodywork, and I found nice and beatten up zx12r fairing, with lights and the visor,

<table style="width:auto;"><tbody><tr><td></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od 27. sije&#269;nja 2012.</td></tr></tbody></table>

I am in the negotiation process with the owner, I am not in a rush so I am dampening the price Iff I buy this mask, I am going to chop it to pieces, I really only need the lights and the surrounding parts of the mask, the rest is going to be fiberglassed in with the rest of the bodywork, which I still have to source Fun stuff.



P.S. I am sory for my dislexic English, I seem to make a lot of typos, but I am doing my best

Wow, nice project! Keep us updated on your progress as you go along.
Tony

Thank you for the support ;-) I sourced the brand new wiring loom from the ER6 so it is getting chopped into peaces tu suit my mutant bike build

I also sourced the yamaha xt 600 steering ( wheel - *uck, I can't remember the english name for the thing that you steer with on the bike- ha ha ha ) and acerbis hand protectors for 25 $ so have to wait for about 2 weeks to get them. Meanwhile I am preparing the frame and the wheels for propper sandblasting. The temperature here is -10 celsious, so I am not going out of the house tu fiddle on the engine untill it gets warmer, at least to zero

Good luck on the build. I had a zx6e back in the day and it was a brilliant road bike. Equipped with a pipe, jet kit, and advancer it would run with its contemporary 750's with vastly better comfort an range.

Yes, I am quite pleased with the bike performance as well. I did cca 6000 kilometers this summer on the bike in such a beatten up condition and it is insane, especiall between 12-14.000 Rpm, not bad for a 22 year old The bike doesn't have any modifications on it except full yoshimura exhaust sistem - 4 in 1 + too loud pipe, which I silenced in the nearby Akrapovi&#269; service. It was 117 decibels, now it is 94 but it still gets my girl deaff. ( And I am not complaining because I don't actually hear her screeaming into my ears )

I know it is a lot more interesting with pictures

Well, I had a pretty interesting afternoon. I decided to service the forks, and well well, I opened the left one, no biggy, drained, dissasembeled, 5 minutes work. I started to dissasemble the right one, and the top plug wont depress, the ring is stuck as shit. I used the biggest rubber hammer in the house, 1400 grams ( cca 3 lbs ) and started to pound the shit out of the sucker but it wuldnt budge. I disconected it from the lower clamp and whadaya now, the little coc#sucking prick of a Previous Owner failed to mention that he "REPAIRED" the bloody thing. It was hidden under the lower calmp. He actually straigtened the fork tube in a vice or something. I don't usualy dissasemble the bike's forks when I am interested in buying it, so " I failed to notice " The new Fu&#%g tube costs around 10$ and he risked his own life ( not to mention a courtesy of at least telling me when I bought the thing ). I am gonna sucker punch him if I see him again, and then I am going to buy him a beer. And then I am gonna rape him... ( just kidding, I am getting a little bit graphic because a bent and not fixed fork is not something you don't mention when you are selling a 150 mph bike )

Ok, I got it out of my system now

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/_sUXDii0F6VfNPcYNdWHRNMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-NKhhoIQSoV8/TymjGGLonJI/AAAAAAAAArI/9p4otydbsDI/s800/DSC05419.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/QkLqkFTJhl5Vt7t7WslJ4dMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-d0CJMGSSOGk/TymjIHHcHuI/AAAAAAAAArU/GHFz1H6aO-8/s800/DSC05420.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/IkrjjPD_zjFMCwqUKXl8b9MTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-ADm1OYIvdCA/TymjGCMwyMI/AAAAAAAAArE/jqVY4ZOnMPA/s800/DSC05422.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/CCx4wstsrmhtKICjDW531NMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-sb7BAX6jq1E/TymkQTMRlEI/AAAAAAAAAr0/cC9sVj3pPho/s800/DSC05423.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/PEfPP3aXfTGF38dexMAQ_dMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-xi_rGJTl6b0/Tymj1L6AItI/AAAAAAAAArk/WAmPIOyk3yY/s800/DSC05426.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/WNAX0jrd3f_QP7mFNVKJ29MTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-wQlWvjw2FI0/TymkNMSIbVI/AAAAAAAAArs/zElJW2MgfKM/s800/DSC05428.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/x49yP72KQAkckp7LHpC9D9MTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-9UG8nIUnInA/TymkT5WUePI/AAAAAAAAAr8/Vbn7HC_hCZs/s800/DSC05429.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>



Lets get constructive. I didn't really like the zzr forks, because they are pretty much the most basic type of forks that you can get. I really like the idea of the USD one, so I am going to research a bit to see what bike front end would filt my bike without too much brain surgery. This means I need the front forks, clamps, brakes fender and bunch of other lovely stuff, or I am just going to source a straight zzr fork tube for 10 $ and get on with it

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/i9DALY5_Vx2nOPopi2A7cNMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-vmONeTr4eH8/TymjqZikYfI/AAAAAAAAArc/FdbsAuPeg1o/s800/DSC05427.JPG" height="800" width="450" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

Well, at least it has got some interpretation of prgressive spring in it I can't wait to see what is in the right one, when I grind it in half tomorow with a grinder I bet it is filled with some sponge and used condoms from some strange gras smoking ritual the previous owner used to attend

This is gettin really funn

One of the best engine ever built... I had a 1993 Fuchsia and purple ZX-6 E that I traded in for a brand new 1999 SV650, back when. I missed the motor from that bike, it was one of the fastest engine built from Kawasaki for a 600 ever!!!

Good luck with your restoration!!

Thanks ;-)

I am not sure if it is the fastest, but it is out there. I started this project because all of the "legends" that people said about this 600 bulletproof engine. I heard stories of 110.000 mile bikes that are still going strong without mayor faults, so that was enough for me. I don't need a rocket, I just want to make a comfortable and fast touring bike on my own specs

I have been drinking around for the past few days, and when I got home this is what I found

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/TRjaVRZm35yjOvSSTZ6bRtMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-fd1B_SOobPk/Ty07PxtvrPI/AAAAAAAAAsI/kmmtIxhnoyY/s800/DSC05433.JPG" height="450" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/q_YXFbgxXLMP39lZH_giltMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-8I6pk0p1I34/Ty07VIBPBKI/AAAAAAAAAsQ/YPRxsiPXZHg/s800/DSC05434.JPG" height="450" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/UoegQStvC6iGXB6XSdSOTtMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/--Li3Rc_HeDo/Ty07bq_seOI/AAAAAAAAAsY/x-DelQ9Erkc/s800/DSC05435.JPG" height="450" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/xLnBlXSfwB6NPSQ9xwatbtMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-NKJ2TJ6Rl5U/Ty07xD5u7NI/AAAAAAAAAso/RUFz4OOoucc/s800/DSC05436.JPG" height="450" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

<table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/IvkK9jKireB7zqqchZY3QNMTjNZETYmyPJy0liipFm0?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-2tL5hz_aR68/Ty07v5r0XDI/AAAAAAAAAsg/LE3-5TeVuck/s800/DSC05437.JPG" height="450" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">Od <a href="https://picasaweb.google.com/116369394113342690084/27Sijecnja2012?authuser=0&feat=embedwebsite">27. sije&#269;nja 2012.</a></td></tr></table>

So I wrapped it up, I am waiting for the warmer days to start the engine, most of the next updates will be on the frame and suspension

bloody alcohol