ZXR 750 makeover

I whipped the shock out today to measure it up against a gsxr 1000 one that I have. Unfortunatley the gsxr item is 20mm shorter, so I now have the option of machinging a new linkage for the top, which isnt too difficult or sorting the original shock out. I will get some prices for the original and take it from there.
I went to remove the swinging arm, but cannot move the spindle through the frame, I am not sure if it is threaded into the frame. It started to rain at this point and I lost interest and put it back under its cover! I will consult the manual later and hopefully remove the swinging arm in the week for a few alterations.

 

I am slowly gathering parts for the rebuild. Got a swinging arm cheap and a swinging arm spindle from a zx7r which is a bit lighter than the zxr one. Also picked up a zxr750K petrol tank (which is aluminium) and the single seat unit.
Swinging arm spindle has a collapsed bearing and will not move even with a lump hammer, so I am going to attack it with an angle grinder this weekend (hence the need for a new swinging arm and spindle!)
Last but not least, I have a nice new stubby end can to go on. I will probably cut the link pipe down a bit to bring the whole thing forward about 3 inches as well.

 

sounds good mate, if you need a hand with out im only round the corner, give us a shout!

 

Tried a few parts on the bike today. I quite like the green and black and may do the whole bike in those colours.



Here is the aluminium tank and the new filler cap I bought for it:



I need to start putting it all back together, but I have been offered a zxr 750 K engine for 250. The engine in the bike is a J model and Kawasaki restricted them to 100hp, where as the K model was the homolgation engine and has a close ratio box, so that may go in as well.

 

Startin to come together now. Just a shame it is not a winter project i have stripped my bike down to clean it and it should be back together this week as it took the place three weeks to do the wheels.

 

Not had a chance to do much with this recently. I have however sourced a free zxr 750 K frame, swinging arm and subframe. I have removed all the bearings from the frame and swinging arm and will be having them shot blasted and then powder coated black. I just need to remove the bearings from the Aprilia rear wheel and then I can send all the powder coating to be done.
I have also acquired a radial master cylinder and pazzo lever from a Yamaha MT 01 for the price of £65 and a radial clutch master cylinder from a ducati 999. Hopefully I will be able to start building up the rolling chasis in the next few weeks.

 

The frame and swinging arm are now off at the powder coaters to be done satin black. It is a company in Haslingdon and I have not used them before, but they specialise in bikes and kit cars. If they do a decent job I will get them to do the wheels as well.
I am removing the engine from the original frame this weekend and have done a deal to have it stripped down and rebuilt and the cases all blasted in exchange for making some swinging arm extensions for a bloke who drag races a blandit.

 

what year is that???? looks good in black.
ive just got same bike - intend to ride it for a bit over winter then rip it to bits for a trackbike, no lights etc...
what are the 6 pot calipers off etc?
interested in getting the brakes as good as possible obviously - i havent even rode it yet, just revved the tits off it in the garage lol - can't wait to get out on it!
also, what exhaust is that>>> im not having a good time trying to find a set of headers for mine as they are rusted to fk underneath, nice shiny chrome on the link pipe & can tho
picking some zx9r headers up this avvy so hopefully i can get them to fit, but they have a link pipe rather that the straight through 3 bolt affair... any tips appreciated

i'll put some pics of mine in a separate thread once its back on the road - just got to put fairings back on now but dont see the point in doing that til ive sorted a set of pipes otherwise i'll have to take it off again lol.

yours looks great :thumbsup:

 

Mine is a 91 so it is a J1 model, it has the twin hoover pipes and no ram air unlike yours. The system on mine is a micron, I may be selling it at some point, but I need to get some money together for a different system first. The zx7r and zx9 down pipes do fit, but they sit a little lower than the zxr ones. I think there may be an issue with them hitting the fairing but have never fitted them so I am only going by others experiences.
The calipers are from a gsxr 1000 K1 I think from memory. These will be for sale as soon as I have cleaned them up as I have a different front end to fit. I think you have the same forks so they will fit. The ZX7R went to 90mm hole centres and a common mod is to convert them to 4 pots. I think the 6 pots on the zxr are an improvement over the standard calipers, but maybe it was because I stripped them down and rebuilt them before I put them on the bike. I also changed the master cylinder and bought steel lines.

 

nice one bud - got a 3 bolt micron on mine & it sounds ace!
i just bought some zx9 headers, ss ones, fkin mint for 15 quid lol theyre going on in a bit. i heard they can hit the fan???
i'll see in a bit.
i'll have them calipers off you tho when you're getting rid - mine has got the 4 pot ones on atm and already has ss hoses.

 

I got the frame and swinging arm back from powder coating this week. Before they went away I took a few brackets off that I will not be needing and smoothed off the rough casting marks where it hand been sand cast as I have seen frames that look a bit pock marked when they have been powder coated over rough castings. I think it was time well spent and the results are better than I could have imagined. The people that did the powder coating are bikers themselves and I think that shows in their attention to detail in their work on my parts.
I will be ordering new bearings this week so athat I can start rebuidling the rolling chasis and clean my greasy finger prints off the frame!

 

looks a quality job that does... very nice work. :thumbsup:
just watch you don't chip it when you put it back together! :banghead:
best to use washers either side of every bolt imo as it stops the coating getting twisted and cracking off when you torque the bolts up...
bought some discs for mine the other night off a guy in oldham who is doing the same rebuild to an L1 - looks great so far...
depending how i get on with this bike, i might end up doing the same myself, but for now it's just getting ragged senseless til it falls apart!
letus know if / when you decide to part with the exhaust - patched my headers up for now but they will need replacing before too long.

what you doing with the paint btw??? restoring to standard or a custom scheme?

interested in what you're doing with the bandit sa.... have a m8 who drag races a firestorm and is currently looking at options for a longer swing arm for it.... he wants it extending a few inch to incorporate the standard tensioners and brake stay, plus weld on an over-the-top sa brace off a blade.
let us know if you have any suggestions... or if that's summat you could do - on a budget as he's recently lost his job

 

I really like the Kawasaki France colour scheme in the green, white and red, but I think it has been done to death, so I have decided on keeping it stealth black with a touch of red. The forks I am using have red sliders and the rear disc I have made has a red anodised centre, so I will strip the front disc centres and have them done in red other thyan that it is black all the way!
As soon as I find a set of Muzzy headers, I will flog the micron.

 

I put lots of bearings in today, made the most of the cold weather and left the bearings in my garage and bought the frame and swinging arm inside in the warm. The bearings almost fell in!
Over xmas I want to get it up to a rolling chasis and start putting the engine in. I have located an L engine which has a bit more top end grunt than the J so will put that in.

 

I made a new top and bottom shock mount today, I am using a shorter shock and needed the top mount to take that into account and the bottom one is based on the dimensions of a zx7r and is supposed to sort out the rock hard suspension of the J. They need anodising and then can be put on the bike.

 

nice machining skills you have - impressed

 

Yesterday I made a set of spacers for my bike. The swinging arm tube on the ZX7r has an aluminium centre and weighs considerabley less but is a little shorter than the zxr 750 item which is a hardened steel tube. The spacers take into account the different length and look a little prettier. Overall a saving of just over a kilo.

 

I stayed behind at work tonight to make the tie bars. I used some offcuts of 7075 that we had left over from making the sump guards for some prodrive Suburu imprezza rally cars. Once I have made the yokes I will send it all off for anodising.

 

very nice m8