Project:- Create a decent track day tool.
The Doner - 1994 ZXR400L
I bought the bike off Ebay from a ZXR breaker...
complete bike minus engine/carbs/exhaust/oil-cooler. £700
The Motor
Kickstart has to go...! The actual motor has a full re-tune to various specs and was built from my stack of parts.
First Impression
Looks like it will go...but you can see why Kickstart is surplus..!
Lets get on with it..!
Fitting the motor..?
The Race seat with seat frame chopped and a new centre support brace.
Rear Shock...ZX6R
Exhaust Pipes
Fuel Tank
Blank off old tap holes and braze in BSP fitting. The steel nut is brazed into the tank..the brass hose fitting
has a taper thread and screws into the nut.
Clutch case
Cut off old kickstart lump and weld in a flat plate.
The Sprocket Cover
The cable interferes with the frame....cut down boss and shorten inner...a bit more to go..!
Quick check on Progress
Not Bad so far...and not taken too long ... about 2 weeks
Revised front mount...
Cradle to use original engine mount. Done as a large curve to miss carbs and get under generator, necessary
because the ZXR hanger is alot further back than the original RD frame start point for down tube.
The pic makes it look alot more 'circular' than it really is.
Battery, Servo, and Plumbing
Again, using parts from my spares...!
CDI/YPVS
Have welded some brackets to bottom of tank and mounted cdi/ypvs. should be nice and cool under there
with those air pipes. Easy to connect up too through gaping hole in front of tank.
COILS
Lower coil in the same place as stock..didn't want long plug leads. Upper coil on top of cradle crossbar.
Spagetti
Voltage reg on left frame spar....throttle and choke cables still to fit...!
Clocks ETC
Kwaka speedo and temp guage ..RD rev counter. This lot was the most painstaking to do..!
Fuel Pump
Looking back at Fuel pump....shorten pipe on QD connector and job done. Harness run is OK.
Poured some fuel in the tank and tested it with carbs connected up...no leaks...floats seem to hold back fuel
without needing smaller valves.
Plugs easy to get at...!
First attempt at air boxes....just need something for Oulton in a weeks time
ASDA tupperware boxes..hehehe welded together with my soldering iron.
