Jim's ZXR750 Build

[JimZXR]

I'll say first off that this will most likely be a long build due to the usual restrictions of work, kids, wife, money, etc!

But in saying that I've managed to finish two builds on the same type of bike in recent years (1 road, 1 track) so I'm confident this one will get finished, sometime.

The bike I've decided to fighter is a 1994 ZXR750 L2, previously green, white and blue. My road bike is in similar colours so that can scratch the riding itch while the fighter is being built.

My plan for the bike is to keep the 750 motor stock and go nuts on the style. In the future I would like to throw a 900 into it for the rideability but for now the 750 will do.

Styling wise I have already got a mask headlight from MildersMasks in the UK which has set the scene for the build which I hope will include a MildersMasks front guard, belly pan, upswept seat unit and an Acewell dash blended into the tank. Paint scheme has already started with the headlight mask so gone try to follow that along the build.

I've attached some photos of the mountain I have to climb!

I'm always open to opinions, criticism and advice as this is my first build and I will most likely go wrong several times before its complete.

[timbo]

Looks like your off to a good start with a solid plan

[Yella]

Nice

[Gix11]

Nice. Keep it coming mate!

[JimZXR]

Went to fit a ZX7R swinger I have (realise it's not much different but does away with the torque arm) only to find its missingn the inner sleeve!

New inner sleeve and bearings for that swinger to pay for now! On the plus side it's one thing that doesn't need any more work!

[Yella]

I think I have a spare one somewhere in the shed

[JimZXR]

Mate; LEGEND!

Do you still have that good shock too? Will bring over those rearsets for you to try?

[Yella]

Yep got the shock in a tub. Sounds good

[JimZXR]

PM me your number again and I'll try to head over to yours by the weekend.

[JimZXR]

Decisions decisions!

Buy off the shelf or attempt to build full custom? That goes for the tail unit, front guard and belly pan.

With little experience of building bike parts from scratch with nothing more than forum threads and YouTube for guidance I have concerns I'll make a dogs dinner of it!

But on the other side it'll cost me $300 almost for the seat unit I want to be flier red and it'll still need modifying to fit!

[Yella]

what sort of tail unit?

[JimZXR]

I spotted a German style unit in the UK for £75 but they're quoting £95 for delivery! And with it being a standard item it'd need a lot of mods to make it fit and to fit the seat to it.

Thinking of hacking up a ZXR race tail unit I have to make that into what I want but need to do some more planning first.

[Yella]

Thats the go

[JimZXR]

Just picked up a set of Pirellia Diablo Rosso tyres, new 430 chain and M4 carbon can for $220 from the MCA sale!

Winner!

[TillerRider]

would the chain be a 530? because 430 seems mighty small lol?

[TillerRider]

oh and you look like you have great ideas for the build, can't wait to see the rest of it!

[JimZXR]

Ah, yes 530! Pudding fingers on iPhone!

[JimZXR]

Finally got a rolling chassis together!

Small step maybe but it gives me chance to look at the bike on its wheels rather than just stands. Big thanks to Yella for the swingarm and shock.

Next step is the tail unit I think and I've been told Santa may have an Acewell dash for me and just possibly some time for my tank with Ben at ExtremeCreations for a recessed mount.

[JimZXR]

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[JimZXR]

Bought moulding foam today so gonna have a crack at making my own seat unit; not sure how this one will end but suppose it's worth a try!

[Gix11]

Good on ya mate. Everyone has to have at least one shot at making their own tail piece.

[JimZXR]

Did a quick and rough "photoshop" of what I'm thinking of, ideas/comments?
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[Gix11]

If the white part is infill then it is going to look very bulky. This can work in a "bull terrier" kind of look, so as long as you keep everything stumpy it will look pretty tough. If the white is just a void area and that black line is the subframe then you're on to something for sure!

[JimZXR]

Sorry; white/grey area is just fill where I couldn't match the background.

Gonna start trimming up the tail unit tonight and then start forming up the new unit.

[JimZXR]

Anyone got any advice where I can find aluminium box section or square bar? Got a mate who can do the fab but I want to give him the materials so I'm not taking the piss too bad!

[latheboy]

Action Aluminium is who I use, there will be plenty of suppliers around.

Make sure you get a grade that welds nicely if it'll be welded.

[Yella]

I get mine from
Action Aluminium
87 Victoria Street,Smithfield NSW 2164
P 02 9604 4866

[Yella]

Easy metal at Wetherill park is another you can get any size and they will cut to size

[JimZXR]

So after months of procrastinating and saving for the impending arrival of son number 2 I've bitten the bullet and put the OEM seat unit back on rather than slow the project any further by trying to create a single seat unit from scratch.

Since putting the original seat unit iback on I've come to like the look of it again so aren't too bothered by not finishing the custom seat idea but I haven't given up on it yet completely, more just wanting to get some momentum going with the rest if the build while that parts comes together more slowly.

A set of billet triples is on the cards from the UK at a very cheap price but have to figure out where to relocate the ignition switch as they don't have a bracket for one.

That's about all the progress I've got to report on so far but hopefully it'll start to pick up again as I'm hoping to be roadworthy for the first time I get a ride out after our son arrives.

[bluedrags]

Keen to see what you do buddy as I'm in the middle of building a 94 zx6.

[JimZXR]

Gonna try to do a front end swap between my 2 bikes this weekend; Standard ZXR750 front end put back onto the faired road bike and the adjustable ZX7R front end onto the fighter.

Not much of a change but it's what I've got on hand and it has 6 pot brakes and the forks were rebuilt recently too so it should be a good swap.

[Project650]

Nice build!
What's the name of the headlight and how's the light output on it?

[JimZXR]

The headlight is a Milders Masks Sketch.

I haven't wired up the headlight yet but I'm told it's decent. Unfortunately for me they've started fitting HID lights as standard on their masks now but my order was delivered before the change.

Great company to deal with too.

http://www.mildersmasks.com

[JimZXR]

So after saying I'm on a limited budget, (blah, blah, blah) I made a trip to ExtremeCreations only to look at a rear disc that it turns out wasn't available I've walked out with a shiny new Acewell Digital dash! That place is too tempting to walk out of empty handed!

In saying that Ben have me an old expansion tank he had laying around as he had no use for it! Top bloke who I'll be seeing again for a tank recessed mount for my new Acewell once funds allow!

[Yella]

Dangerous place that

[JimZXR]

So now my faired bike won't start so gotta sort that out before I do anything on the fighter.

Still waiting on parts to come in before I can do my front end swap then hopefully things will start moving again!

[JimZXR]

So son number 2 has arrived and is giving us the usual sleepless nights and tiresome days but during my time off I've managed to get a few things done while I'm waiting on parts to arrive and deals to be done on parts I'm looking to buy.

I finally bit the bullet and put an angle grinder disc through my rear subframe The. Having a mate weld it up to shortening it quite a bit but still retaining the standard rear light bracket and a few of the mounting holes for the tail unit. I've also decided to have a chance ack at reshaping my OEM tail unit by beating it up and reforming it by hand to suit the new shortened subframe. Not too sure how it'll work out but from the small bit I've had a try with the heat gun it's come out pretty good some I'm hoping it won't look too shit once it's finished!

[JimZXR]

Just missed out on a pair of forks and callipers fur my fighter; bugger! Ah well, should have a set available in summer from another source so all remains well.

[Gix11]

The grinder was the big step mate; you'll be on a roll from here.

[JimZXR]

After taking the step of chopping the subframe I've decided to get eBaying and have picked up a new rear light with integrated indicators and a belly pan.

[JimZXR]

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[JimZXR]

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[Gix11]

Yep, that's the way.

[Yella]

Nice

[JimZXR]

LSubframe cut and dressed ready for welding!

[Gix11]

I just realised the photos are upside down. That had me confused for a bit!

[JimZXR]

Just done this really rough "photoshop" of what I want the tail to look like once I'm finished. Since I'm keeping all of the OEM mounting points in confident it can be done but then again nice been wrong before!
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[JimZXR]

Plus, anyone know if a ZX7R 'P' motor will slot into my ZXR750 frame? Yella?

[Gix11]

That looks good mate. Are you going to cut and plastic weld the original tail unit?

[JimZXR]

Going to try.
Then probably lay some fribreglass on the back for strength.

[Gix11]

Just a bit of advice from past experience: don't mix plastic and fibreglass. Even though they bond and look good when you create it at stand still, they will crack apart with movement during riding as they react differently to vibration. I found out the hard way after weeks of making the tail and then it falling apart after the first ride. Had to start from scratch with a fibreglass mold.

[JimZXR]

Thanks for the head up, any suggestions on how to brace the new piece?

[Gix11]

"Brace the new peice"? You mean the subframe change or an addition to the tail plastic?

[JimZXR]

bracing the plastic tail halves. I have plenty of spare plastic so will cut that into strips

[JimZXR]

Well, still waiting on my mate to weld up my subframe so decided to try out some brake callipers and an MC I had laying around.

Brakes are original to the bike as is the MC (rebuilt) and forks (need rebuilding) so fitting up wasn't a problem but like always when I bleed brakes these ones seem like they'll take some felting to get the feel I'm after. Bled up using syringe and down using remote bleeder and have got some lever feel but right at the back. Got the lever strapped back overnight to see if that helps clear it then I'll push some more fluid up tomorrow. Failing that I'll start looking into a pressure bleeder.

Silly thing is these brakes/forks/MC aren't for the fighter, they're to swap with the parts on my road but which are destined for the fighter! So in a way I suppose I'm making progress of a sort!

[JimZXR]

After a night with the lever strapped to the bar the brakes have become much better.
Still not got the feel I want but a few more flushes and nights with the brakes hard on should bring it up to where I want it.

[JimZXR]

Ordered steering head bearings today and am looking for someone to do a fork service for me for a reasonable price; any recommendations?

[hooligan]

trooper Lu's.
about $500 for a rebuild with new springs and shims to suit.
They have done the front forks on my KTM 640SM which was so good they did the forks on my MT09, also brilliant. And an MT09 is complete rubbish to start with.
Don't quote me on the price though, i don't work there.

[JimZXR]

After advice from Yella I've gone with DoctorR1 in St. Marys.

Picked up my head bearings and have started to strip back my brakes for cleaning so it's finally moving , slowly, again.

Big things to fix soon are my road bike engine (caughing oil into cylinder 1 and 2) and the suspension.

Once the engine is fixed I think I'm there mechanically it's then just aesthetics.

[Yella]

Sweet good guy old Terry

[JimZXR]

Certainly is mate; picked up the forks today now I'm in talks with him to diagnose my engines misfire as I'm at a loss!

Give it a few weeks and some good nights in the garage and I might even have something resembling a running streetfighter as I'll have the suspension, brakes, motor, bars, levers and whatnot almost all together then it's just down to bolting to all up and then starting the styling!

Hopeful, but not confident yet!

[JimZXR]

So after a short hiatus from the fighter build my hand has now been forced as I low sided on my faired ZXR on Tuesday evening. The results being a battered bike and a broken collar bone for my trouble!

With that I mind I've decided to not repair that bike yet and concentrate on getting my fighter project finished.

Good news is my triples arrived from the UK, mirrors are ordered and I'm already slowing in bolting and fitting parts to the frame, albeit mostly just the very easy stuff as I only have use of 1 good arm!

[JimZXR]

So after two weeks of laying up trying to rest the collar bone I've managed to slowly pull off all of the unwanted plastics and brackets and start to pull the front end apart but obviously can't do the major swap to my custom triples with one arm so am waiting for a mate to get some free time.

I have however tried the top clamp into the bike and I think it looks amazing with the underslung mirrors and drag bars.

Really looking forward to stripping it out and getting the triples and light on properly.

[JimZXR]

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[hyofighter]

Looking good . I did the same with the mirrors on the yzf but i had them mounted inboard of the controls still underslug thought it looked mint but it fowled on the tank when lock to lock was a shame

[BOBBY]

I've got underslung mirrors thanks to nick76 and they look good IMO. Work well too. Exactly like yours. They give it that cafe look kinda.

[JimZXR]

I can't wait to ride it to be honest but I've had another small setback recently and am overseas for a week or so.

It's all good though.

The for mounts for my headlight came in before I left so hopefully when I get back I can start swapping the front ends and getting some brackets made to fix it all on proper.

[JimZXR]

So I'm back in Australia after a week in the UK and am still suffering with the broken collar bone but with the help of a good mate doing the spanner work we've got new bearings, new triples and front end with most of the controls but have yet to fit the brakes, lines and MC.

Hopefully by the end of this week we'll have the brakes fitted and he can give it a ride for me.

After that I've got to get the tank recess sorted for the Acewell dash then sort out the wiring which I'm not looking forward to!

[JimZXR]

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[Yella]

Sweet coming along nice

[JimZXR]

Managed to get the brakes fitted tonight but unfortunately had to revert back to my non radial MC as the lines I currently have aren't quite long enough to reach the radial.

Going to bleed it tomorrow then hopefully it'll have enough pressure to be ridden around the corner to my new place by a mate.

It's far from ride out ready but if it can be moved safely across my estate I'm happy with that for now. Plus I'm not allowed to ride until at least the new year!

[JimZXR]

Tried to start now just have the solenoid clicking so got battery on charge overnight to see if that helps!

[JimZXR]

So my startin issue turned out to be a miss connected clutch switch.

Now that's back on properly the bike starts and runs like normal but unfortunately I'm still under a riding ban while my collar bone recoups so a mate is gonna ride it for me sometime this weekend and let me know how it goes and what might need adjusting.

Once it's rideable I've only got the indicators, headlight and dash to fit then by that time hopefully I'll be in good enough condition to ride it myself.

[Gix11]

Getting close mate. Good feeling hey!?

[JimZXR]

Awesome, so much better than when it was faired.

[JimZXR]

So after some sweet talking I've managed to get a short run around the block on the bike without causing WW3 in my house and I'm so happy with the results.

The bike feel so much more nimble and eager to turn than with the clip ons. I'm definitely gonna need a steering damper though.

Even with drag bars fitted it still feel comfortable and the lack of the fairing gives so much more confidence in viewing the road ahead.

[Gix11]

You'll never go back now mate!

[JimZXR]

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[JimZXR]

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[Nudie]

Fuck that looks mean!

You healed up yet?

[JimZXR]

Getting there slowly mate, still on a self (wife) imposed ban until I heal up more so trying to make progress with it while it's laid up.

Pity too as it's still road registered and doing nothing!

[Nudie]

Yeah that's got to suck. But we need time to heal, so look after yourself!

[JimZXR]

After some thought I decided to move on my spare bike to another ASF member to add to his stable I now have a few more $$$ in the bank and far more space in my garage.

With some guidance from Yella I'm now back onto the build path but have to be softly softly due to still carrying an "minor" injury from my recent crash.

I've got to swap my swinger and wheel for a ZX7 item which gives me a 190 wheel and deletes the torque arm that I've never really liked.

A few engine issues aside I'm only waiting on some help to make a headlight bracket and a few little bits off ebay then some help from Yella again to install my Acewell and clean up the wiring.

Hoping to be ready before rego is due but doubt it'll be ridden in anger for quite a while by me at least.

As for the "minor" injury; 4 and a half months after my off my collar bone is still in 5 pieces, not healed and I'm needing surgery so that's a bit shit!
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[Yella]

Glad I can help :)

[JimZXR]

Had a fairly productive day today;
Wheel and chain off,
brake and torque arm off,
all suspension nuts undone,
exhaust shield off,
cut back the undertray and started prepping the ZX7 swinger to go in!

Still figuring out how I'm gonna support the bike in order to take the swinger out with the engine still in but I think I'm almost there.

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[GammaBoy]

Sawhorses and a length of fencepost through the subframe?

[JimZXR]

So wound up using a large head trolley jack under the suspension linkage but this needed the linkage removing completely which in turn needed the radiator and exhaust system taking off so it took a while to get sorted but changing the swinger after that was pretty easy but removing the swingarm pivot bolt was a nightmare that only got solved with a heavy hammer and some "gentle" persuasion!

With the rear ended done I got into the engine and replaced the leaking clutch pushrod seal and while I was there decided to change the oil and oil filter so once I replace the radiator and coolant I've done a little service before Winter.

Next steps will be to replac all of the above then replace the chain and Cush drive rubbers. Hopefully then I can give it a test ride and look at fitting the belly pan and headlight.

[Yella]

Nice

[JimZXR]

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[JimZXR]

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[JimZXR]

Got a bit more progress today; replaced and hooked up the battery, tightened shock top bolt, ordered adjusting washer for front sprocket (to move it out to line up with the chain on the wider wheel), replaced and hooked up the tank, removed the grab handle, installed the integrated clear tail light (indicators built in) and installed the tail fairing sections.

Starting to take some kind of shape now but plenty of distance to go yet!

[JimZXR]

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[JimZXR]

Really like the look of this undertray too; ebay here we go again!

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[Gix11]

Great to see a build topic still going strong! Seems people have forgotten about build topics. Cheers Jim.

[JimZXR]

Progress is a little slower now due to waiting on parts but got the front sprocket on and lined the chain up.

Also wired in the integrated rear light. Pictures are a tad blurred but you get the point!

[JimZXR]

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[JimZXR]

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[JimZXR]

Now the project is starting to take shape again I'm turning my mind to the headlight and although I have the mask pictures. Slow I'm considering the Sachs twin (too&bottom) headlight unit or even going full 90's with twin dominators...

Any ideas from the crowd?!?

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[Gix11]

I'd say go with the mask unit you have with regrads to looks. The other two may give a bit better light but they have been done to death, and the twin dominators are almost a joke. That's my opinion anyway (you did ask!)

[Yella]

Yep stick with the mask just gotta figure out how to mount it