Damo's ZX10R

[IW84NO1]

Rightio

first build thread so apologies if I make a balls up of the photos but here is the story so far, this was the first day i got it.
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Over the years i did the usual, ditched the reflectors, changed the pipe, chucked some go fast bits on it and powder coated the rims black
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[IW84NO1]

After a few years like that i bought some apex clip ons, longer brake and clutch lines, bar end mirrors and chopped the screen
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this was fun to ride around on for a while, but now its time to man up and do it properly. This is currently how it sits at the moment

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[wackyrider]

Nice one Damo. What's the plan for the bike so? Just handlebars and headlight or looking and doing some more mods?

[IW84NO1]

Be nice if its that easy haha, so far i have found i gotta get rid of the ugly overflow bottle, have to relocate the key barrel as it will prob interfere with the headlight, still undecided on the headlight setup as i don't want to block the ram-air, black out the forks and lower clamp, hoping to retain the original gauge so will need to jig something up for that and also relocate the steering dampner.

Hoping to just get the essentials done now where it looks reasonable and rideable, then just plod along with extra bits when the weather is too shit to ride

[Gix11]

Mate, that looks like it's going to be good!

I'm guessing you have checked here for inspiration... http://www.streetfighters.com.au/forum/showthread.php?9296-Kawasaki-ZX10

[IW84NO1]

Yea i have perused those pages a few hundred times

[IW84NO1]

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shitty overflow bottle gone, got rid of some of the fairing brackets that are no longer gonna be needed too

[IW84NO1]

alright so onto the mission of fitting the bars, im not 100% sold on what ive done here so i welcome any criticism, the top triple clamp was hollowed out underneath so i got some of this from supercrap
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Piled it in there, tried flattening it out before it set
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[IW84NO1]

didnt think much of that putty, so i milled it flat and knocked up some 8mm plate to use as giant washers
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Hopefully it holds together, next up cut the key barrel holder off, give it a tidy up and bolt her up

[ozzy1100]

Dude that will be more than fine, it should outlast the human race
Depending on the yoke a big washer on the bottom side is sometimes enough

[Gix11]

Yep, what Lynton said.

[IW84NO1]

Sweet, gives me a little more confidence, will run with that then

[LKC73]

Awesome, its looks like a good start mate.

[geesexar]

Top work

[Azrael]

Wa represent! Nice steel weld job on the top clamp. if you need any welding of fabrication (ally also) hit me up man.

[IW84NO1]

cheers, will do

[IW84NO1]

Quick question, whats the consensus with mounting something in front of the intake? There doesn't seem to be a lot on offer for mask setups with vents. Its not going to be doing the same sort of speeds it would have done fully dressed so the ram air may not be as relevant anymore but would it affect the day to day sort of stuff?

[LKC73]

Damo, this one would suit a ZX10,
https://gemo-fighters-shop.de/epages/ecb2f89a-9c5f-4e47-98a1-98ac174e4b29.sf/de_DE/?ObjectPath=/Shops/ecb2f89a-9c5f-4e47-98a1-98ac174e4b29/Products/0200-99

[IW84NO1]

yea i like the look of that one and would probably end up going that way, was more curious if the mask didnt have the mesh on the front would it affect how the bike runs

[LKC73]

It really shouldn't affect how the bike runs. As they have all types of grills stock and channels. The only thing that may affect it is if you have a sensor in the air channel.

[IW84NO1]

well, bit the bullet and ordered the Gemo mask tonight, little bit exciting

[rod185651]

very cool

[IW84NO1]

Has anyone ordered parts from Gemo Fighters? Ordered the mask setup a month ago, had a replay the next day asking what size my fork tubes were for the mounting kit and that they had a lot of orders so delivery time may be longer but nothing from them since. I replied to the email with the size and asked what the rough ETA was a couple of times now still without a response.

Dont mind waiting for it but would be nice to know for how long, there website states that the mask is in stock and delivery time is 8 working days but i suspect its probably not updated.

Any one had similar experiences?

[LKC73]

I'd be no help, I used them back in 2008. I do think it was around 4 weeks but they may have needed to make my seat unit back then.

[Gix11]

Back in the hey day we had a bunch of German guys on here that could have sorted that for you. I think one guy even worked at Gemo or knew the owner. I would try emailing again.

[IW84NO1]

Ok, so after an email asking for a response or a dispute being lodged with paypal i heard back from them saying it was almost finished and will be sent this week, then half hour later another email with a dhl tracking number. Doesnt register on there website but so ill give it a couple days and try again

[LKC73]

Hang in there mate, they don't stuff people around as far as I know. Gemo back in the day sent my seat unit after making it and took 6 weeks from memory.

[IW84NO1]

xmas came early, needs a bit of a cut and shunt but looks pretty good sitting there
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[LKC73]

Looks great and I love those ones! Keep up the good work mate :)

[IW84NO1]

cheers

fixed the mask setup properly today, this was as close as i could get it without fouling on the intake when turning the bars, hopefully when its all blacked out on the front it wont stand out so much, othrwise the grinder will come out
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Fuck me this thing has some wiring, whole roll of black electrical tape gone today, found somewhere to temporarily mount the ignition barrel untill i come up with a better plan
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lights are all hooked up, cables run through the bars for indicators, it even fired up and ran after a quick strip down to find a plug that hadnt clipped together properly

happy days

[IW84NO1]

front view

[LKC73]

Question, Are you ever planning to put this thing back to stock? If not, why not trim the intake to allow more room with fouling?
Or do you want to leave it just in case? Just asking, thats all.
again, looks really good and the key relocation looks good to.

[IW84NO1]

I cant see myself ever putting it back the way it was but i guess at the moment its still possible (couple of parts would need replacing). Once i start chopping into the frame it makes it a little harder, plus the mask would need trimming back aswell to keep the lines with the fork tube.

Ill re-asses once everything is painted and see how it looks, if need be it wont take too much to trim it back

[LKC73]

I was just asking, I think its pretty much spot on how you got it. and wouldn't be chopping into it to fit it tighter.

[Gix11]

Looks great mate. Nice work.

[BillyWhizz888]

Cant wait to see this in the car park at work and also at the WAFR OOOOOOH, did I just say that :-)

[Bob]

Nice one mate.

[IW84NO1]

Not really fighter related but picked up a loan bike from a fella at work that i can use until the Ninja is finished or he decides to finally get his license. Not a bad looking bike.

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[Gix11]

Fuckin' 'ell - That's some loan bike mate! Nice work. I used to get CB400s or BMW shitters as loan bikes.

[IW84NO1]

Yea was a good score, was giving the bloke a hard time about never riding and taking so long to get his license. Jokingly offered my services of looking after it for him and he said yea no worries come get it. I usually shadow him on rides anyway so at least im keeping the cobwebs off of it for him, plus he just got himself a new mustang so anything outside of that hes not too interested in.

[IW84NO1]

so have got the cluster mounted, bought some more fat bar clamps and just flipped them over, this was the first go but it sat wayyyyy to fucking high
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so i rejigged a few things and got it a little lower, will see how stable it is when riding, might have to brace it a little more and also get used to the cluster moving with the bars rather then being fixed like before
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even found a spot to mount my garage door opener
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[ozzy1100]

Now that’s handy

[Gix11]

Too right. Nice work mate - Coming together well.

[Bob]

Looking good mate. coming along great

[LKC73]

That's nifty mate. You'll get use to the cluster quickly being where it is. Keep up the good work mate ;)

[IW84NO1]

cheers fellas, my el cheapo ebay indicators rocked up yesterday so will see how they go

[IW84NO1]

got the indicators fitted and took it for a blat, pretty much just around the burbs, put some fresh fuel in it, pumped up the tyres. Fuck yes, nothing fell off.

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Then back into the shed

[IW84NO1]

even though there will be mesh on the holes in the mask i still wanted to cover in the intake on the frame so i went on a hunt for some mesh, didnt need a lot so i didnt really want to have to buy a roll of it.
Bunnings FTW!!!!


Before
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After
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[LKC73]

Top Idea mate. I actually used alloy stuff from supercheap cut to size.

[IW84NO1]

yea Supercheap was actually my next stop if Bunnings didnt work out haha

[IW84NO1]

picked up the mask last night from the painter, he was spose to paint the mesh aswell but forgot apparently. Looks ok at the moment but once everything is blacked out on the front it may need painting also

[IW84NO1]

another with a bit better light

[LKC73]

Nice, look great and I dont mind the contrast of the mesh. But see how it looks all blacked out mate.

[Gix11]

Hell yea! That looks great.

[ozzy1100]

I’m liking that

[IW84NO1]

So after riding it for a day i stripped it again, the rusty headers and the non blackness up front was rustling my jimmies. while i was at it i whipped out the old dan moto muffler i bought back in the day and played around with the fitting
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looks better already on the ass end without the pillion pegs, i was hoping to mount the yoshi in the same spot but its wayyyyy too bulky, might give the moto a repack, piss the carbon look alike skin off and ceramic coat it. Oh and thanks to the 7 year old daughter who reminded me the radiator had been removed before i went to start it to see what it sounded like with the different muffler.

Too many beers

[IW84NO1]

wrong photo, here it is without the pegs

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so now im accumulating bits to get powder coated/ceramic coated/painted

[Gix11]

I'd have that rear hugger off in a heartbeat of it was mine. It'll complete change the look of it (and yes, open it up to shit getting everywhere, but hey, practical doesn't always hit the spot. - I mean, what the fuck does a car bra do for looks?)

[IW84NO1]

Funny you should mention that, was thinking the same thing when i was fucking around down that end. The front one isn't much better either so both have made my list of shit to fuck with.

[IW84NO1]

So in the interest of saving money and because im fucking impatient i had a go at painting some bits myself, found this at supercrap, got it in black and a clear coat

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read in the small fine print about how it needed to cure for an hour at 200 degrees, bastard wouldnt fit in the oven so it was time for a fry up on the bbq, dont worry about the furry shit on it, was still a bit tacky and the rag stuck to it

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fitted her up along with the freshly painted radiator

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[IW84NO1]

Next up will be removing all the casting marks and painting the upper and lower triple clamp, was going to powder coat but that metal putty shit i used is temp rated less then what it would be baked at, plus i would have to remove the steering stem bearings which have only just been replaced, stay tuned

[Gix11]

Shit yea, that's the spirit!

[LKC73]

Going well mate, the more you do yourself the more appreciation you'll have of bike. Keep up the pic's mate.

[IW84NO1]

bits painted and its back together, put the yoshi back on it so i can ride it while i knock up another muffler. Going to put it through its paces next week when im on RnR, burn all that excess paint off haha

[IW84NO1]

couple more snaps

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[LKC73]

Looks wicked mate. Absolutely think you knocked this out the park. Top job.

[IW84NO1]

cheers mate, fucking love this thing now, cant wipe the smile off my face when im on it.

[IW84NO1]

started on the exhaust now, pulled the ends off of the dan moto muffler and the packing was pretty much shagged. Got some 3 1/2" stainless exhaust pipe to use as the outer shell which was slightly thicker so had to take a lick out of each end on the lathe.

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taking it to work tomorrow and see if the boily can tig the tip on for me, will drill and rivet the other end with some fresh packing.

started messing around with a muffler tag idea, muffler will be black with the tag polished or another colour, havent decided yet.

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knuckles with a jigsaw piece, bit of a autism awareness snuck in there

[Bob]

love the look mate. nice job

[IW84NO1]

Exhaust is on, sounds reasonable but has made it a little doughy down low, might have to get it re-tuned. Will give it a paint in the next couple of days but will eventually get it ceramic coated with the headers, the paint on the headers pretty much flaked off straight away after i put them on and started riding

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[drewboy]

Nice work Damo, that looks tidy as! You going to ceramic coat the muffler and headers at the same time? Still going with the knuckles on the can?

[IW84NO1]

yep ill get them done together so it all matches, Ill give the knuckles a bit of a polish up and fit them after the coating is done

[Gix11]

What did you paint the headers with again? Seems weird it would come off first go if it was HT paint.

[IW84NO1]

it was a dupli colour high heat stuff from supercrap, had ceramic in it and supposedly good for 1100 degrees. Have to admit the prep work wasn't sensational so it may be more a faulty workmanship rather then shit paint

[Gix11]

Fair enough. Oh well, at least the ceramic coating will save the day.

[IW84NO1]

yup, once the weather turns to shit the exhaust will come back off and receive the professional job, untill then, as long as people maintain a 5 metre perimeter, then they wont notice

[IW84NO1]

Muffler painted, while it was cooking on the bbq i got bored and started fucking around with a belly pan chopping up the original one. front of it still needs trimming to suit the lines of the bike but it will do for the 500k ride on Saturday

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[drewboy]

Muffler came up a treat mate!

[IW84NO1]

Cheers,

So the belly pan wasn't as stable as anticipated and broke one of the mounting tabs during the run, luckily was close to home and managed to limp it back without damaging it. Wind protection sucks no matter how much i tried to tuck in under the speedo, i knew that was gonna be the case after stripping it back but wasnt prepared for how bad it was during the "spirited" runs. The steering dampener needs to go back on also, had a bit of head shake during said "spirited" runs.

Nothing like a day out with the Hayabusa boys to iron out any potential bugs, back in the shed she goes

[LKC73]

Looking Killer and love the belly pan. Hope you sort your issues. Wind however will never be your friend on a fighter.
That's just fighter life for you LOL

[IW84NO1]

haha lack of wind protection is a sacrifice i'm willing to live with

Got the steering damper fitted and shes back on the road, now to beef up the belly pan mounts

[IW84NO1]

so finally got the damper mounted, kinda, was the best idea i could come up with at the moment, any suggestions??

its functional, not the prettiest looking setup, definitely needs to be blacked out

[Auser6guy]

Would dropping the forks 10mm and putting it above the clamp help? I know it’ll change rake and trail...
Else the way it is on mine (er6, yes i know not even similar but i have z1 forks :) )I use a z1000 top clamp and an eBay mount kit
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[Auser6guy]

Else there’s top triples with the mount integrated. I’m yet to see one with bar clamps but they can be had fairly cheap...
As an example this ones for a 6er but might fit
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com.au%2Fulk%2Fitm%2 F401730898889
Has the added benefit of removable ignition mount

Downside, made from chinesium.... for 50 bucks how good could it really be ?

[IW84NO1]

If i drop the forks the top of them would hit the bars, i spose i could chuck some spacers in there and raise the bars higher to allow for that, i used the original mount for it that bolted under the top triple but it sat on the piss when he bars were straight which fucking drove me crazy

that one on yours looks like a mini pillion peg bracket haha

cheers for he ideas, something to think about

[Auser6guy]

My z1000 forks sit 30mm above the triple and i used risers on my clamp to clear them

i had to then get even lower bars and i really liked how drag bars felt as they have no rise but normal sweep and generally are nice and wide(800mm!) ive since gone for clip ons for a more aggressive look( im also going with better and fatter zx10 forks as well) so youre welcome to the bar for the price of postage.Or else you can order on eBay for like 30 bucks delivered.. these ones are closer to standard width but theres wider ones as well
https://www.ebay.com.au/itm/7-8-22mm-Motorcycle-Bike-Drag-Bar-Straight-Handlebar-For-Honda-CG125-GN125-/183924803637

[Auser6guy]

Now that you mentioned that it looks like a pillion bracket i cant unsee that hahah!

[IW84NO1]

hahaha sorry mate, cheers for the offer but i should be good for the bars, the bend on mine aren't too aggressive and i reckon a combination of spacer under the risers, winding down the pre-load a bit and maybe milling a couple mill off of the fork bracket i could probably get it to fit above the top triple .

[Auser6guy]

Hi mate, do you still have the stock bracket for the damper that fits under the top triple and are you willing to part with it for not a lot of money? I can swap my mini pillion peg bracket if that helps?

Reason being I put zx10 forks on my bike recently(with clip ons) and now my old set up sits to high

[IW84NO1]

Shit i have only just seen that last post, my apologies. I think i still have it in my box of bits but i chopped it up at the start trying to fit the damper