Zzr600 budget build Updated 4th April

[sharky]

Thought I'd start this as an example of a budget build.
Starting with the wifes slightly bashed zzr6 ([:I] dropped it off the trailer).
http://www.streetfighters.com.au/forum/upload/104617601924663.jpg

It needs to be WOVI inspected (as it was a repairable write off in Vic) and Safety Cert'd so it will be thrown back together stock first for the tests.
The Ins company has agreed on $1400 less xs which gives me $1050 to play with. This is the payout from the trailer incident claim.. Was going to be a stock rebuild...until I picked up some parts for a mate and one thing led to another.....
http://www.streetfighters.com.au/forum/upload/104617601921584.jpg

So a quick word with owner of said parts and a squirt of paint.....along with my old headlight unit......
http://www.streetfighters.com.au/forum/upload/104617601917923.jpg

This has given it a seat height of just 690mm (lowering links fitted) which suits my 'vertically challenged' wife perfectly.
Also lost about 30-40lbs of plastics etc, most carried high up.

The aim is to get this up and running for the $1050 plus the resale of all the un-needed bits. As the plastics are no longer made they might be worth a few bucks.....hopefully.

[Pab13]

Nice work on that budget and your wife should like it being a bit lighter

[sharky]

Cheers Pab. Gonna be a challenge....but thats half the fun. She has said she will pay for the paint work herself so that frees up some cash.
First job is to get it running...carbies piss out fuel when the tap is turned on...been sat sooo long they're all gunked up.[}:)]

[TurboKat]

*In my best AbFab voice*
Ooh, those 916 seat units are just sooo 2001 Dahhling [:X]

[sharky]

Yeah, but it was free and she loves it......;)

[latheboy]

She Loves It .. hehe

[sharky]

I don't really care....Gonna be more interesting than just rebuilding it stock...........

[BANDITROD]

top work sharky should be perfect for her mate

[Issues]

Let me know about the head light n bits, some of it should fit my 1100

[sharky]

What bits are you after ? It will all be available after the engineering/safety thing.

[sharky]

Bikes all back together...mmmm exhaust waaaaaay toooo loud..[:0]..
'hunts around garage for summat'...[}:)]...
'V' can fits the hole perfectly...cut of ring pull end, drill 4 holes in base...insert into orifice and hold in with a bolt.
Paint inside black and Voila...nice legal cans..[^]..

http://www.streetfighters.com.au/forum/upload/18142597719632.jpg


http://www.streetfighters.com.au/forum/upload/18142597731910.jpg

Told ya this was a budget bike :D
Only got to last for safety test...not even being ridden to test...no reg etc...to much aggro

[fimpBIKES]

that must be HEAPS QUIETER

poor bike [XX(]

[sharky]

Sounds like a stocker....can't be arsed to have any problems with safety cert...

[Issues]

quote:Originally posted by sharky

What bits are you after ? It will all be available after the engineering/safety thing.


After a headlight, mines chipped, n maybe indicators as spares. The plastics look different n are proberly to narrow

[LKC73]

Nice work sharky! I like the look of it mate, well done.

[sharky]

Well.......got the Safety cert today no problems....except a weeee 'lil one...
Bike was running fine when mechanic went out for test ride...when he returned it was on 3 cyl's and knocking noise coming from motor.:(
Not really sure yet what it is.

Story is...

Tried to start it up in garage....gave up fuel pissing out of carbs.(fuel pump pumps when cranking)

Try again next day,started up...ran perfect, warmed it up and fan kicked in. Turned it off.

Started next mornin...ok...load onto ute, go for safety cert.....
AND BANG !!!

Only thing I can see is the sight glass is a bit full so maybe fuel got into the engine.
But I'm puzzled as to why I could run it up ok only for it to die a couple of days later.
Could it be the big ends shagged 'cos of the fuel ? Mechanic suggested a broken piston ?

Anyways I'm watchin a no rego damaged bike on Evilbay and hope to grab that for a cheap price, nick the motor for hers whilst I 'fighter it and then rebuild her motor, swap 'em back and put her bodywork on the damged bike...and make a huuuuge profit :D

Oh and does anybody know if you need a running engine to get your WOVI certificate ?

[Jockney Rebel]

Russ mate it didnt lock up on ya did it when you were turninit over i tend to go with yer mech mate it might have had a hydro lock on one of the pistons and fucked it you did say it was 'makin' oil

[Hillsy]

quote:Originally posted by sharky


Oh and does anybody know if you need a running engine to get your WOVI certificate ?


Not sure about that - but when I took my ZX9 there I had to leave it with them and was not allowed to be present at the inspection. There weren't any K's added to the clock, though so I know they didn't ride it (well, not far anyway....)

Theoretically they are only looking for legit replacement parts and shouldn't be interested in the mechanical condition of the bike - the Safety Cert covers that....

[BOHEMION]

Russ, if the V can fails, I have a proper baffle you can have mate. I just gotta find it.

[sharky]

Thaks Boh, but hopefully I'm sorted now (safety cert wise).
If they want the engine running for the WOVI then they're out of luck.
Just hopin to win the Zzr on ebay[:p]

[sharky]

So..the zzr on ebay is a repairable write off (V-checked before bidding).:(
Drained the oil on wifeys and Yes, there is petrol in the oil so I'm guessing its a bearing issue making the clonk noise.:(
I can't see any shrapnel in the oil yet..got it filtering through a cloth to see whats in it.

I'm wondering...any other engines that might fit...ZX7r etc
Any ideas Kwak Heads ?

[TurboKat]

The engine from the new ZX 14 'Busa <s>eater</s> <s>destroyer</s> slayer (;)) will bolt straight in Russ, Trust me [^]

[fimpBIKES]

:D

[sharky]

Won the evil bay zzr.
Now a question ....
I swap the good engine into wifeys bike (already got the Safety cert bloke sorted) and get the WOVI cert & rego it.
Rebuild her original engine (with a few tweeks maybe [}:)])
What's involved as far as the rego when I swap the engine back over ?
Do I need another safety cert ?

The plan is then to put ebay bike engine back in, use wifeys bodywork ([:0]) to make it good and then sell it for a huge profit.....well cover engine rebuild costs anyway.

So she gets a refreshed motor for free...and I get to spend many hours in my new workshop 'going downstairs to work on YOUR bike darling'

[sharky]

Jeez...what a pig to get the motor out....and then had to do it again.....
http://www.streetfighters.com.au/forum/upload/12349382744441.jpg

So I've decided to leave to the leave the ebay motor in the bike (long as it proves good). Got some other good parts from it too (better than on hers).

Quick squirt of black satin on the frame and charcoal met. on the motor. Exhaust will be sandblasted and painted later.

Should be fired up today and then off for WOVI this week sometime.
Gonna go onm hold for a week or 3 'cos we have to move house .

[sharky]

All sorted. Spent xmas and boxing day swapping engines over.
Got the new safety cert and it has now passed WOVI too so once she's got it rego'd its party time [}:)]

Gonna have to wait 'til I set up my spanky new workshop :D but that won't take long.

If anyone knows anyone who is after zzr6 spares get in touch, I 'll have lots of bits for sale soon.

[LKC73]

quote:Originally posted by sharky

All sorted. Spent xmas and boxing day swapping engines over.
Got the new safety cert and it has now passed WOVI too so once she's got it rego'd its party time [}:)]

Yes, thats all well and good, but pictures would be great!

Also sharky, I seen another ZZR600 on ebay that went down the road. He was starting it off at 2 grand! Now I seen this bike go down in person (3rd on the scene) and there wasnt much left of it that could justify 2 grand I tell ya!

[sharky]

? The first page shows the concept bike.....
Now its passed both inspections I will be making a start...once we have moved 'ouse....
And the zzr that crashed...D'ya know what it sold for ??

[sharky]

So,finally made a start. The subframe has been cut'n'shut and I'm in the process of bracing up the rails. Then its undertray time...

http://www.streetfighters.com.au/forum/upload/31530004634796.jpg


The ali welding hasn't been too bad either..not for a mig anyway.

http://www.streetfighters.com.au/forum/upload/31530004634812.jpg

[zx12argh]

Hey Rus - chased my mate up again - he's got the screen, I'll see if I can pick it up thursday night off him. Sorry for the slackness mate - this is a crazy time of year for me.

[sharky]

Thats 'cos you've gone from student life to the real world mate ;)
Cheers Pete

[LKC73]

Nice tail section Sharky, but help my newbieness out and what tail is that from?

[sharky]

Its the old classic mate...916 solo seat

[LKC73]

quote:Originally posted by sharky

Its the old classic mate...916 solo seat


Thought as much, but didnt want to make a complete dick of myself and try and guess, better off asking. Looks good to mate, but i thought the idea of the ZZR was to get your lady on a fighter, not to play with it in the shed for so long hahaha..

[sharky]

Cheeky bugger ! Only started workin on it last week. Its been rideable for months.[:p]

[Jockney Rebel]

its lookin cool russ ..pity she wont let u ride it once its built tho lol

[sharky]

So, been a bit busy....

http://www.streetfighters.com.au/forum/upload/74562848848123.jpg

Temporary drag bars from electrical conduit....

http://www.streetfighters.com.au/forum/upload/74562848848145.jpg


Might have to persuade her to have an Acewell speedo...not much room for nowt else..


http://www.streetfighters.com.au/forum/upload/74562848827281.jpg

I'm think a black 'GT' type stripe to break up the silver (her colour choice, not mine)
Exhausts need a kick up to match the seat unit.

[WarHound]

I am thinking about a ZZR .. is it a good bike to fighter up in your opinion ?

[rod185651]

Looking good mate, after a week of having one myself I think an acewell speedo is definately the go. Any plans for the chain guard?
cheers Rod

[sharky]

Not bad Warhound....just gotta sort the ram air intakes and the water works.
Gonna go for an acewell...mines great too ;)

And...suprise suprise....she wants it to go back to black. :(

[Gix11]

Sharky, I've got an acewell lying around here that i never used if you want it? Cheap of course! One of the original ones Ben was pedalling.

As for her changing her mind.... that's birds for ya.

[sharky]

Sold mate, if its the rectangular type. I'll ring ya later on today.

[LKC73]

Nice one sharky! I'll be thinking about a ZZR when its time for a project! They look killer stripped down! The black did look alot better though....

[sharky]

Gone for a charcoal grey...Hope she likes it.

http://www.streetfighters.com.au/forum/upload/95466919636648.jpg

Cut down stock mudguard...the shape kinda matches the screen...

http://www.streetfighters.com.au/forum/upload/95466919639166.jpg

[WarHound]

Do you think you could cut the ram air intakes back to the frame for looks ? Maybe rig up some mesh over it from there ? Not too sure what to do with the one I have as yet because it needs to be cleaned up and serviced first .. running really rough. The other thing is I have plans .. if I can ever make them happen to take my GSX750F and turn it into a sleeper tourer ? for want of a better term .. throwing a RF Swinger on with Busa Suspension and a Busa Rear Wheel, (190) or maybe a Bandit (180), 92 GSXR upside down forks and a bandir motor .. but keep the bike looking pretty stock. So the ZZR will have to remain standard for me to ride until I finish that project then I would like to make the ZZR a full fighter .. stripped down naked machine. There doesnt seem to be a lot needed to do to it as its already light weight and zippy. 8) ... anyways thats my plans now all I need to do is learn how to do some of the things I would like to ... find someone to help me learn how to do them, or win lotto and hand them both to Ben LOL

[descendingfear]

Looking very nice how long has it taken you to get this far?

[Fish]

do those acewell dashes allow for cable speedos? I just got a GPX250 thrown at me for the right price (FREE) and think i might pretty it up a little. I think those zzr600s will make brilliant fighters. good luck lads. when you get them up and going should catch up for a run, lyons road may be a good proving ground.:D[8D]

[Seifer]

Nope, they run off magnets. Ditch the cable and epoxy on an earthing magnet instead.

[zx12argh]

...or grab a sensor magnet off a cnc with a little thread cut into the back of one - mines bolted through the rear sproket. Thats the arrangement I've got on mine.

[WarHound]

Regarding WOVI, I have found the gold coast guy really easy to deal with and a simple process to put it through. I have been told that its not easy through the Brisbane city guys .. I dont know if you are in QLD but I thought that might help

[Hillsy]

quote:Originally posted by Bitchfish

I just got a GPX250 thrown at me for the right price (FREE) and think i might pretty it up a little.

GPX eh? Heres a neat one:

http://www.streetfighters.com.au/forum/topic.asp?TOPIC_ID=9062

I honestly didn't think you could do much with them until I saw that one [:p]

Oh, and nice work there Sharky ;)

[sharky]

quote:Looking very nice how long has it taken you to get this far?
Not long mate...see above...about 10th Feb I got started.

[Fish]

hey warhound have you seen this? http://www.streetfighters.com.au/forum/topic.asp?TOPIC_ID=8553&whichpage=1 just incase you wanted to keep a bit of fairing to hide that bit of frame you don't like.

[Fish]

quote:Originally posted by Hillsy


quote:Originally posted by Bitchfish

I just got a GPX250 thrown at me for the right price (FREE) and think i might pretty it up a little.

GPX eh? Heres a neat one:

http://www.streetfighters.com.au/forum/topic.asp?TOPIC_ID=9062

I honestly didn't think you could do much with them until I saw that one [:p]

Oh, and nice work there Sharky ;)


Hmmm interesting. I would have removed the stickers that say KAW on one side and SAKI on the other but that's just nit picking.;)

[sharky]

Finally finished (for now at least)

http://www.streetfighters.com.au/forum/upload/77683117576651.jpg


http://www.streetfighters.com.au/forum/upload/77683117592554.jpg


This must be the ultimate budget build as it has cost.............................Nothin :D
I had the insurance payout $1400,less the excess, which was $300. Bought another bike for an engine $1800 and spent a good lump with Stu.
I then sold off eveything not needed via ebay and got all my money back including ebay fees.
Lots more that can/will be doe but for now she just wants to ride it.

[Weaselman]

mucho surprissed man... looks damm good without fairings

[Iceman]

Top work Russ.

[JackTar]

Well done Sharky, good job mate.

[ozkat]

Well done Russ, that looks bloody great.

[TurboKat]

& here's me thinking Sarah couldn't possibly be any more attractive [:I]
Now she rides a KAWASAKI STREETFIGHTER [:p]
She's FAR too good for you Rusty. ;)
Top job mate, & all for no money... you sure you're not Scottish?

[BANDITROD]

fuckin awsome sharky top marks mate

[Hillsy]

Just needs the can cut down and angled up a bit to make it spot on IMO

Nice budget build though Sharky - what's the screen off??

[sharky]

Lights and screen from Stu at AuSFR

[zx12argh]

Good work rs - looks good in one piece mate ;)
Glad to see your missus has taste even if you don't with those yammies [:p]

[sharky]

She must have good taste....She married me [^]

[Gix11]

Nice one mate. Came up a treat hey?

[Learnatic]

Top job,we will just have to get out there now,I'm keen for a ride this weekend.

[Jockney Rebel]

quote:Originally posted by turbokat

& here's me thinking Sarah couldn't possibly be any more attractive [:I]
Now she rides a KAWASAKI STREETFIGHTER [:p]
She's FAR too good for you Rusty. ;)
Top job mate, & all for no money... you sure you're not Scottish?
oi .....:D

[Jockney Rebel]

quote:Originally posted by sharky

She must have good taste....She married me [^]
...well taste of some sort anyway:D ...nice job mate ...must talk to you about your experience in getting sussed out up there in sunshineland ..the missus was well impressed with the gaff and we may be thinkin about a move
be afraid be very afraid :D

[sharky]

Anytime mate...I'll pm ya me number