Kawasaki ZX6D - ZZR600D build thread

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This season I am going to keep this stupidly loud joshimura exhaust, but next year, I have to put something more ear friendly

<a href="https://picasaweb.google.com/lh/photo/iF0apuTcHLQmeLbe-Rm7FVD8JWupE5GJ20_DWRFinTI?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-0s6Le9dbuXE/Ub32gsegX1I/AAAAAAAABcs/aqQTkArFeMg/s800/P6160043.JPG" height="600" width="800" /></a>

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Here is me on the bike, finaly

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Chekong the ergonomics

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This would be ideal, but the final position will be somewhere in the middle

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Like your upgrades & resto so far, they really are great all around street bikes.
Haa haa and I am not the only inmate still riding a ZX6D! There must be some connection between D model ownership and backyard rebuilds. Here's mine halfway through a four day marathon overhaul two weeks ago before taking off for a week long trip.



Been running perfect, kept mine closer to stock than yours, I appreciate the luggage hooks on the stock tail & helmet lock a lot. Comes in handy running around downtown Montreal grocery shopping

I'll be watching the thread for updates!

Come whenever you want, just tell me when, so we can meet for some beers if we are near

About the handlebar.. I think you need something more like this, maybe with risers...
This were the stock handlebars of my previous NX 150 (This is the best photo of their position I could find)



And a closer look of them when I took them off for painting..



Hope it helps..

This is the handlebar I will use, I just need to get some time to pick it up

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My last bike was versys, so I like the upright position. Thanks for the tip

Nice bike you have there ;-) And I like the amount of beverages ;-) What happened do your rear blinkers? I had to saw mine off because I can't fit the givi lugage holders with the stock ones

I think it was N.American regulations for just the D model, but the rear blinkers on mine are stock. Here the integrated blinkers & tail did not come until 1993.

Oh, and mine has 170k on her now. The various bits are getting tired, but the motor still gives me a grin every time I give her full stonk

THE best single mod you can do though is a better rear shock. Either find a used Hagon or a ZZR12 (there is a big difference between a ZZR & ZX). The ZZR shock bolts straight in, with remote preload.

Any ZX6D questions feel free to ask me, in five years and 140,00km I have refreshed or rebuilt just about everything on my bike!

Thank you for the help

I will definitely contact you one of these days when I put the carbs back on, I will have some questions regarding the carbs stock settings, so I will have to tune them up from scratch. I have cleaned them last winter, and they have been sitting in my drawer for the past year, and honestly, I forgot all of the settings

A lot higher than mine..

I was refering to something like that!
Hope it helps with the ergonomics

I like the seating position on the bike allready with the yamaha xt handlebar but my girl likes to ride with me aswell so it is more comfortable for her to get in the more upright position so she can rest ger back on the topcase, like this

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somewhere in the middle will be ok

Today I started to clean a gass tank. I removed the gass, cleaned all of the shit out of it with fresh water few times. After that I modified one of my old 800 wat PC power suplies and took one 12V 24amp rail, cut the connector of. I connected the + lead to the sacrifficial anode, in this case an old rusty screwdriver, and the negative lead to the part of the tank with the bare metal protruding through the paint. I am going to leave it like this for three days, changing the water and sodium carbonate solution once a day, and changing the anods, and changing the minus lead position on the tank to get the best current flow around the tank. I think 24 amps wil be more than enough to clean this bastard There was some rust in the tank, so I hope that this proces will make it all nice and shiny once again

<a href="https://picasaweb.google.com/lh/photo/jCyYY0KTkOIOrkHFUDCUa7-qavuGhwL4KZTTQ8Z0kHk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-mFQKcLgHYSk/UcCYHArR9gI/AAAAAAAABhQ/o1O0lvgb1RM/s800/P6180020.JPG" height="600" width="800" /></a>

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I used an old plastic spraypaint lid as an insulator

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after only 20 minutes, there is result That is why computer powersuplies kick ass comparing to the standard battery chargers

<a href="https://picasaweb.google.com/lh/photo/Ooyf0X8f1oJwXJEt_ZGhqb-qavuGhwL4KZTTQ8Z0kHk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-CwzEPl9i__A/UcCYIxx8JGI/AAAAAAAABhc/5bEsmCkc9zg/s800/P6180023.JPG" height="600" width="800" /></a>

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In all of the basement I haven't managed to find single peace of metal that is not stainless so the old rusti metal screwdriver had to go

Well, finally, I managed to find couple of spare hours, get in the car and go to Austria to pick up some of the remaining missing peaces for this build

Here is the lucky pray that i bought

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Finally I got the handlebars that I wanted from the start. Nice rise and 900 mm width for good control on the gravel and snow.

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I got me a nice handprotectors with integrated led blinkers. I am not to sure about the functionality of those in the case of fall, but they said that they are made of virtually indestructible plastic. I hope I don't find out the limit of the "virtual" part

<a href="https://picasaweb.google.com/lh/photo/s0rZtMkCECEXz2PqMSRCjB5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-lG3E9OXf9SU/UcQGLknpkuI/AAAAAAAABkY/6EC7I3jC35I/s800/P6210033.JPG" height="600" width="800" /></a>

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One of the biggest concerns on the bike the previous owner "modified" were the headlights. They were some H11 sets from a toyota pickup truck, and there was no low beam, only double high beam which drained a lot of power and couldn't get MOT pass So I found an really sexy looking peace of a headlight. It has a led ring around it which is a running light, and a standard H4 low/high beam pattern. I think that it is a bargain for a 100 euros

<a href="https://picasaweb.google.com/lh/photo/Lq0YSyB5e8Be6lSyLHY-fR5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-nPoOErYzSvE/UcQGDFBqB1I/AAAAAAAABi8/KQg6fA_EQIU/s800/P6210020.JPG" height="600" width="800" /></a>

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This is how it will look like at night

<a href="https://picasaweb.google.com/lh/photo/N46-df7zfe0QYfT_xeoMZB5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-kQkDdIifso0/UcQH4kFqfLI/AAAAAAAABlk/8smUO4cIq-s/s800/lampa.jpg" height="752" width="800" /></a>

I also wanted a LED rear light for the improved visibility and mainly to minimise the electric power on the bike. I didn't want those fancy small lights, so I found a standard sized one with a licence plate light integrated aswell

<a href="https://picasaweb.google.com/lh/photo/5J1sBophtgZHYnymC6hSMx5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-dhgoLcIKUxI/UcQGEm2SkXI/AAAAAAAABjQ/O9F6TWhwxRg/s800/P6210023.JPG" height="600" width="800" /></a>

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Since I like to ride my bikes in the snow a lot, I also like to fall 10 times a day so i found a nice plastic and CHEAP plastic folding mirors

<a href="https://picasaweb.google.com/lh/photo/X0pEX0ZV5mS5oZuxjp8bpB5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-Yo515PKUjq4/UcQGGhekaII/AAAAAAAABjo/SkEQQQWgui4/s800/P6210026.JPG" height="600" width="800" /></a>

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I got a pair of really basic light holding brackets which I am going to cut and shorten, because they are to big for my needs

<a href="https://picasaweb.google.com/lh/photo/sAyNadvXouP3AUOAQJPy6R5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-6C8XH36rfOw/UcQGJA9VGxI/AAAAAAAABj8/dLnokVXatOA/s800/P6210028.JPG" height="600" width="800" /></a>

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And the main part that I was really annoyed with on the "original" bike was the "speedo" or lack thereof.

On the right is the original monstrosity, sawed in kalf, cut and riveted to death by the previous owner

<a href="https://picasaweb.google.com/lh/photo/qK8Fk-EvWULJAySD3FgToB5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-O5gYvYu0NNg/UcQGNxgvASI/AAAAAAAABkw/L2hvDvWpmSI/s800/P6210035.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/bU4FC_frAK8EZdy5Qxco4h5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-Do3yuatiHqo/UcQGNpb74aI/AAAAAAAABk4/3MkREoz8w80/s800/P6210036.JPG" height="600" width="800" /></a>

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Old was a massive chunk

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New one is feather light

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I wanted this little peace for a long time. It is very basic and informative. It has a speed, RPM, lights, blinkers and fuel, and that is more then I need

<a href="https://picasaweb.google.com/lh/photo/AMbSRHct9UHTphbn1CIggh5HyaRHaepuJVoqWrWrvLc?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-x38cUwmeK8Q/UcQGJZDy_JI/AAAAAAAABkE/pXAgzlHT868/s800/P6210030.JPG" height="600" width="800" /></a>

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I still have to find a mounting position for it. I am not sure if I will mount it to the handlebar or will it go on the top tripple where the key used to be

I also got me an used kawasaki er-6 wiring harness, which I will cut to peaces. I also have a lot of electric wiring, led blinkers relays and other stuff which I need to make my new wiring loom from scratch. I believe that there will be considerably less wire when I am finished with it. I will post pictures of the "loom making" process if anyone is interested I never made a lom for a motorcycle before, but I am quite comfortable with the electricity on boats and yachts, both are 12V DC an waterproofing is much more of a factor on a boat then on the motorbike, so I believe that I will do an overkill on a waterproofing part here, but it will definitely not hurt

Cheers, a lot more updates will come these days, There is a good chance that this bike will be finished soon

And now comes the fun part

I started to mock up all of the parts

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starting with the headlight mounts, they really are way too big

<a href="https://picasaweb.google.com/lh/photo/2vK9-hIbUzX4UaQIxU4ghuCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-GlWAx-0DzCI/UcQnwFkD_RI/AAAAAAAABmI/kEJgwYJW1t8/s800/P6210021.JPG" height="600" width="800" /></a>

I FINALLY finally found a bike stand

<a href="https://picasaweb.google.com/lh/photo/uiHJurVF37NgGJQCV6R5x-CUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-PmTL4yEObuM/UcQnwMQXmKI/AAAAAAAABmA/EaAOlyfZiHc/s800/P6210022.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/7OSELiWYe600896ELXSkmuCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-GacM7XKoQe4/UcQnyRZKxJI/AAAAAAAABmU/Zw8VUgJpd6Y/s800/P6210023.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/gspFzt84lRD7As-Lb5vf_eCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-PMqERlV6rw4/UcQny3cN5iI/AAAAAAAABmc/MgviRXIzTEc/s800/P6210024.JPG" height="600" width="800" /></a>

Comparing the handlebar sizes Yamaha vs. Fehling

<a href="https://picasaweb.google.com/lh/photo/-jr3FBs3u32k4kOgTiU-fOCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-BPNViECNt2k/UcQnzgGnEnI/AAAAAAAABmg/dUruiAqcpkM/s800/P6210025.JPG" height="600" width="800" /></a>

On the bike

<a href="https://picasaweb.google.com/lh/photo/9lu9fpOHBnVkAwlGTecj7uCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-LSFv7ZFHRD0/UcQn0gIUYfI/AAAAAAAABms/Qb9zK0P6BAQ/s800/P6210026.JPG" height="600" width="800" /></a>

and the headlight on

<a href="https://picasaweb.google.com/lh/photo/jl2PrqV0uuZIUH4bbvqt_eCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-LemiKKHev68/UcQn1KLxSBI/AAAAAAAABmw/z404kR4uyto/s800/P6210027.JPG" height="600" width="800" /></a>

this is one sexy looking bike

<a href="https://picasaweb.google.com/lh/photo/Q7rCziZ5E3lu6rOhMYI1Z-CUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-ORzbn5feFdw/UcQn2E9qT3I/AAAAAAAABm4/xQQdWbFR8tU/s800/P6210028.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/dZ-K_DUWFGgAVuOF02RuiuCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-oeNcMzncBSk/UcQn3ncdG1I/AAAAAAAABoQ/gQVDoFq5NZM/s800/P6210029.JPG" height="800" width="600" /></a>

brand new front end

<a href="https://picasaweb.google.com/lh/photo/UwaXbuOoyM95m8_6t1lx6-CUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-xhAIdLVbDJE/UcQn30w2YqI/AAAAAAAABnI/-HztBe8JFTs/s800/P6210030.JPG" height="600" width="800" /></a>

rear still need some work, bit of fiberglassing and it is done

<a href="https://picasaweb.google.com/lh/photo/h-Y3FCEZuR1bO30JWuQwVOCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-2BNxuiP_7_o/UcQn4R4L7FI/AAAAAAAABoY/Si8svdzRmcY/s800/P6210031.JPG" height="800" width="600" /></a>

<a href="https://picasaweb.google.com/lh/photo/11yhHjQFc7s1Yay7dpQqyOCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-l2rw05-gHQY/UcQn65PblkI/AAAAAAAABng/w8yd8BKQE_s/s800/P6210032.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/qAgw5SU0U7UprsYt9rPbwOCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-bTmnPO2Rp2o/UcQn7f6Xv7I/AAAAAAAABnk/LUjaWFs63O0/s800/P6210033.JPG" height="600" width="800" /></a>

And foldable mirrors, I think that I will keep them on the end of the bars like this, so I can have a nice view of the police behind me

<a href="https://picasaweb.google.com/lh/photo/aCVO39e9rar0_ikIeG90zeCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-s6_ZnHGzssU/UcQn7ls4f3I/AAAAAAAABno/y9UCIjfKkGk/s800/P6210034.JPG" height="600" width="800" /></a>

Here is where the rear light will be, and the licence plate will be fully high under the light

<a href="https://picasaweb.google.com/lh/photo/n2M4Lmll7rnb2dKUNyVuj-CUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-mE3vq6OTP04/UcQn8pJf4AI/AAAAAAAABnw/YZ5dqzhGT-0/s800/P6210035.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/7I_k5bVG8Si5o4at7qrT_OCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-BiTjo3tln5w/UcQn9itJRAI/AAAAAAAABn8/az3oSIwIV_0/s800/P6210036.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/p0Y59M07qhSmjRgdoA6fXeCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-03-6rst8k2A/UcQn91q2jnI/AAAAAAAABoA/IU_Udf4NmWw/s800/P6210037.JPG" height="600" width="800" /></a>

Rear end will need to have a lot of work done

Uff

have to post this one one more time

<a href="https://picasaweb.google.com/lh/photo/dZ-K_DUWFGgAVuOF02RuiuCUlt5OxmiLp7-jflib5Lk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-oeNcMzncBSk/UcQn3ncdG1I/AAAAAAAABoU/uXPTbcN3lus/s800/P6210029.JPG" height="800" width="600" /></a>

Please get me one of those handlebars for my bike!

It's really good looking!
Congrats! It's getting better and better every time I take a look at the thread!

Hy Leo, here is the link for the handlebar manufacturer

http://www.fehling.de/index.php?content=preise&lenkerid=6&lang=eng

I am not sure if they have a distributor in Argentina, but I presume that a lot of the manufacturers have something simmilar in their line. I bought this one because it is bombproof an it was really cheap, at aroun 45 euros or something like that.

I am doing some modifications on the stem at the moment, so tmorow I am starting to torque all of the bolts from the ground up and the finall assembly starts