Jim's ZXR750 Build

[JimZXR]

All good Gix; prefer honesty!

Cheers Yella.

Will try to stick it out with the mask but may get something for the interim encase the mask turns out to be a bug bare!

[JimZXR]

So I've bought an undertray and plate holder off ebay; will post up once it arrives.

[JimZXR]

So moving forward I've made up a quick to do list...

Replace coolant

Replace rear fairings

Replace seats

Fit undertray

Fit plate hanger

Fit plate with plate lights

Clean rear sprocket and carrier

Fit Cush drive rubbers

Fit sprocket carrier and sprocket

Fit chain

Pump tyre

Remove front guard and paint

Test fit belly pan and make brackets

Paint belly pan

Cut tab off front brake MC

Refit, fill and bleed front brakes

Make Acewell bracket

Test fit Acewell bracket and Acewell to risers then remove.

Lift off tank and airbox and tidy/trim wiring.

Refit airbox and tank

Fit and wire up Acewell on bracket

Make headlight backing plate from aluminium plate

Fit headlight backing plate to brackets

Fit indicators

Test ride

[JimZXR]

Fair bit of work to do but in reality I think all I have left to buy is a set of plate lights and another set of fork brackets

[Yella]

Not a bad list

[JimZXR]

Cush drive rubbers and chain done tonight.

[Yella]

getting close

[JimZXR]

Bike won't start now!

Killed battery trying to get it to fire.

Battery back on charge for another try tomorrow.

Has been a few months since its fired so may be something simple yet.

[JimZXR]

7590

[JimZXR]

Apologies about the upside down photos; no idea how to make it right on iPhone!

[Gix11]

I was going to say, if it's upside down that's why it won't start.....

Are you getting good sparks on the plugs? Airbox attached properly? All carbs getting fuel? No wasps nests, mouse chewing anywhere? Obvious stuff I know, but just thought I'd throw it out there.

[JimZXR]

No idea on all of the above as I had hoped to get it fired quickly and didn't get time to strip anything down to check through methodically.

I plan on going through a similar list to the above tonight when I get home.

[JimZXR]

i am such a knob; bike now running like a sewing machine!

Decided to start my fault finding with fuel and lucky I did as it turns out my fuel tap doesn't flow very much fuel in the ON position! Turned it to RES and have her a kick and she fired happily after a few seconds turning to fill the lines and carbs!

With the bike running and looking pretty good I'm hoping to get it on the road AND RIDING by summer. Now that seems like an easy timeline but bare in mind I'll be out of action in a sling until the end of Winter!

[Yella]

Sweet that was easy

[JimZXR]

Been looking at the tail end and I'm not happy with the holes left in the tail fairings after I removed the grab handle/spoiler so I'm looking into a repair material called Plastex to fill in the gaps.

Unfotunately it means I'll definitely have to paint or wrap the plastics and tank.

7592

7593

[JimZXR]

Received undertray today so hopefully have that fitted soon.

Plate holder looks way to big so guessing I'll be making one up then!

[JimZXR]

Got the undertray test fitted today

7598

[Gix11]

Much tidier hey. Nice work. Keep it coming.

[JimZXR]

Soon be off to Yella for some wiring then hopefully paint!

[JimZXR]

Before I send the bike off to Yella I've decided to have a custom risers top mount for my Acewell so hopefully I'll have that back in a few weeks then Yella can hook the dash and headlight up and tidy the harness.

[Yella]

Sweet

[JimZXR]

Well; surgery done and just waiting to be discharged!

7622

[JimZXR]

Received a new headlight bracket after a recommendation from another member and they've worked a treat.

I will need to have a set of collars made to centralise the bolts so I've put a thread up at the link below;

http://www.streetfighters.com.au/forum/showthread.php?28010-Need-some-small-parts-making&p=419354#post419354

After a quick test fit I'm well happy with the results but could be improved if it was closer to the forks but for now it'll do the trick nicely.

7628

[JimZXR]

After only a day I've secured a member to make me the collars I need in a reasonable run exchange!

Roll on when I get them and finally get the headlight mounted and ready for wiring.

[JimZXR]

Received the collars I needed and got the headlight mounted and although I'm not happy with the clearance from the forks I'm happy to have it finally mounted properly.

Also managed to get my exhaust manifold back from Melbourne as checked luggage on a flight I took and only cost $13.50!

[JimZXR]

7677

7678

[rod185651]

Headlight looks pretty good, is the photo blurry?

[JimZXR]

Yeah, bad camera.

I'll take a few more and repost soon

[JimZXR]

7679

7680

7681

[Gix11]

Coming together hey? Where are you gauges/dash going again?

[JimZXR]

Top of risers will be an all in one riser top/gauge mount

[JimZXR]

7684

3D rendering of gauge cluster

[Gix11]

Cool! That reminds me of the old EFE dash (loosely of course).

7685

[JimZXR]

Wasn't really going for retro but suppose it'd be cool.

Already got it loosely booked in with Yella for finishing touches but have to avoid hanging around too much as turbos seem to be contagious!

[ozzy1100]

I love that rendering

[JimZXR]

Buzzing to get in here and onto the bike!

[JimZXR]

7722

[Gix11]

...and the magic happens.

[JimZXR]

Before anyone says it I know the symbols for the indicators, etc aren't in correctly but it's what needed to be to make it work the way it has.

I may yet have them removed and transplant some LED's onto the triples or maybe the bars?

7725

[ozzy1100]

much cool

[JimZXR]

Apparently it's in the air as we speak!

So I'm making progress I've been dragging the bike out of the garage and under the Pergola.

7726

[JimZXR]

And apparently hanging it upside down too!

[Gix11]

There seems to be a theme of things upside down or in sideways. You like things unconventional hey Jim? :) Good on ya mate.

[JimZXR]

Fecking iPhone camera!

[JimZXR]

Still waiting on delivery of parts from the UK; itching to get it al back together!

[LKC73]

Nice work Jim, looking very cool. Did you make the CNC dash holder?

[JimZXR]

Thanks.

Not me mate, I bought a set of custom triples off a mate in the UK when he started up his business and he's made me the gauge mount too.

Still waiting on delivery but the tracker says its in Sydney at least!

[JimZXR]

Looks like it's gonna be a flurry of activity to get it rego ready by late this month!

[JimZXR]

7739

7740

[Yella]

Love the gauge, I see you went 50/50 on the picture orientation

[JimZXR]

Fucking hate iPhones!

[MDM]

I've cricked my neck...

[JimZXR]

Started with a productive restart of the build on saturday with a new set of tyres fitted to my wheels and a set of indicators now gracing the front and rear of the bike but al started to head down hill when I tried to mount my bars so seems I've got a small adjustment to make here and there but nothing I can't handle; roll on the grinding work!

[JimZXR]

Made the required adjustments to the risers and all is now good.

The list of things to do is somehow growing the more progress I make with rebuilding the bike though!

Hopi g to have it together enough to go for wiring at Yella's and pink slip soon after.

[JimZXR]

A momentus day; finally got the bike round to Yella'a for wiring!

7746

[JimZXR]

Apparently this is how it looks now!

7756

[Yella]

Yep thats about it until Friday night :)

[JimZXR]

Just heard from Yella; bike is all ready for pick up!

Hopefully be back together and ready for rego by next weekend.

Pictures to follow......

[LKC73]

Awesome Jim, look forward to seeing it done mate.

[JimZXR]

Bike is back at mine and I'm buzzing at how well it came out, too work by Yella.

Getting my list of things to do ticked off bit by bit and will hopefully be ready for rego soon.

Still on a ban from my Mrs until after holiday in November but it'll be ready for when I'm back!

[JimZXR]

Few bits to do but we'all get there!

[JimZXR]

OK, fitted air box and tank, fired it and she ran.

Choke stuck wide open, pushed it back but still need a permanent fix.

Used 'ON' side of fuel tap; leaked, so used 'RES'; got to get a fuel tap rebuild kit.

Started it on 'RES' with no choke; BOOM, she fired! After a few minutes the temptation got too much so I hopped on and took it down the road and back, only the bottom of 1st and 2nd but what a feeling! Can't believe the difference in the comfort and feel of the bike now it's fightered! Mrs isn't too please as I went out without fear on but can see how happy I am so think it'll pass quickly!

So to recap I've fired it and given it a test ride but now have at least two more things to do before it's done, but I suppose only 1 is needed for rego!

Huge thanks to Yella for getting me to this point, kudos buddy!

[JimZXR]

Bought and fitted a chain guard today along with some brackets to hold the brake lines steady.

Got a fuel tap rebuild kit ready to collect at Kawasaki.

Already planning small changes and upgrades to make the bike more mine.

[LKC73]

Hahaha I have that kind of list to Jim, its on a small note pad in my tool box so the missus doesn't see how much I got to do :cool:

[JimZXR]

Picked up the fuel tap rebuild kit today so I can stop the leak soon.

Tightened down the brake line holders so no mor eflapping brake lines either!

Hopefully get the tank back off this week and get the few remaining jobs done under it then can concentrate on the finishing touches for rego

[JimZXR]

OK, so a very productive day today and I've almost got the bike ready for rego.

Only have to calibrate the Acewell dash, torque check all nuts and bolts and for the horn.

Photos and more details to follow after rego and first ride.

[Yella]

Do a wheelie

[JimZXR]

More chance of me pulling a H2 out of my arse!

[JimZXR]

7782

[JimZXR]

7783

[JimZXR]

7784

[Yella]

Bike looks killer and not one photo upside down. Nice work

[Shadowzone]

Bike looks great.

Can you ride it yet or is the shoulder still rooted?

[JimZXR]

Shoulder has recovered but still on a wife imposed ban until after holiday!

[Simo74]

Looking good, nice work

[JimZXR]

Thanks.

Next jobs on the list after rego are to fit the belly pan, fit the undertray, close up some holes in the tail unit, wrap my ZX9R headers and look into a shorty can for a low side exit exhaust like an S1000RR or Fireblade.

[LKC73]

On ya Jim, looking very cool mate. Bet you cant wait for rego!

[JimZXR]

Just rode my bike into work and HOLY SHIT it feels amazing! So much better than when it was faired.

The Acewell dash is calibrated and seems to have me going a tad fast compared to other road users but thinking it's just more accurate compared to their speedos.

Throttle response seemed a little fluffy at the higher end of the revs so thinking it may be a jetting issue as it doesn't have the full ram air system on it now.

Still have plenty of work to do to it but looking forward to having it back on the road again soon.

[Yella]

Mental how light the front end gets with dirt bars

[badboynot]

So true it's awesome! And good job Jim good to see it done for now and then green black plates is something il be doing for my bike looks good

[JimZXR]

Cheers.

Hopefully I can get a few decent rides in before Christmas.

And one for a giggle; I had a noise complaint about the bike from an with our so have to be a little more subtle next time I have it out!

[Yella]

Really??? some people nee to relax

[JimZXR]

Started a new section of the build and test fitted the belly pan.

Needs a bit of shaping but is mostly there but obviously custom brackets are a must!

7801

7802

[LKC73]

Look nice, I like the shape too.

[JimZXR]

Yeah, it's made specifically for the bike so the holes are pretty close and I can see only a few places that I'll need to trim for a good fit.

[JimZXR]

Picked up a Jardine slip on pipe from Hooligan last night to use with my new ZX9R headers.

Going to look at the fitting and position of it before permanently fixing it I place.

I've decided to wrap the pipes too so should look pretty sweet once it's done and apparently this pipe can "wake the dead" with the baffle out so the neighbours are gonna love me!

Who's a good welder/fabricator on here who doesn't mind Frankenstein exhausts?!?

[JimZXR]

Oh My Fucking Lord; that Jardine pipe makes a fine and VERY loud tune!

At idle it was a tad less thunderous than my Tinegate pipe but made up for it when I turned the throttle a touch. Sounds very much like straight pipes with a very slight reduction in noise and violence.

Next step is to find a fabricator to get the whole thing together as one system so I can wrap it all together. Any advice or guidance on the right person for the job would be greatly appreciated.

[Gix11]

Nice one Jim. Coming together nicely!

[The Phantom]

Looks good.

[JimZXR]

Cheers all, it's coming together slowly but next few months will
No doubt be slow due to christmas and whatnot.

Hoping to get the belly pan and exhaust sorted before Santa arrives though!

[JimZXR]

OK, so the new exhaust pipe I bought from Hooligan is ready for collection after a little welding to make it fit in with the ZX9R headers and after attending the bike night at Penrith tomorrow that's next on the list for work. Still think it'all be way too loud but hoping a baffle and some exhaust matting may help.

After that I've got a mate popping round to weld me up some tacks on my subframe so I can get an idea of what it'all take to make a stubby tail unit and I'll also try to shape up some brackets for the belly pan from Aluminium plate.

Wheels are again moving!

[Gix11]

That's what we like to hear. Good stuff Jim.

[hooligan]

Glad the pipe is getting used.

[JimZXR]

It's amazing how drinking beer and listening to music (Prodigy this time) gets the creative juices flowing; think I may have figured out my subframe woes but need to get some sanding/cutting done on an existing subframe next week then hopefully all will come together!

[JimZXR]

So the subframe is with a mate to get welded and the exhaust headers are being moedified to accept the Jardine pipe.

More photos soon hopefully

[JimZXR]

Heard today that my headers are ready for collection so all being well I may have the new exhaust fitted before the weekend is out!

[Gix11]

Hell yea! That's the juice.

[craig]

Looking good. The belly pan a nice addition, I think that's what mine missing.

[JimZXR]

7827

[JimZXR]

Will post shots when it's fitted but can already guess it'll be killer loud!