Kawasaki ZX6D - ZZR600D build thread

Looking good. I like that bar mount plate you made.

btw, cute shop shoes

Ha ha ha, yes, the slippers are virtualy indestructable

thanks for the interest, nice to get some feedback from time to time

I am sure it is nice to have a project for the winters in Croatia.
I have had 2 big surgeries since June 2010 and have been bored to death. If it were not for tinkering on a couple of bike projects I would have taken a bullet or swallowed my shotgun by now.

Keep posting pics and updates.

Just a side note for strength in the bar mount you could go back and drill and tap the clamp bolts through the triple clamp just to add some extra attachment points. Maybe overkill, but I ride hard and better safe than sorry on my builds. I break alot of stuff.

Yes, it is definitely getting two more bolt holes. This should hold fine for a normal usage, but when I drop it somewhere, it will snap right of, so better safe than sorry

For me it is a different story, I work a lot and I am never at home, so whenever I manage to find couple of spare hours i have fun with the couple of projects I have laying around the house, and one of them is the bike. I hope that I will manage to build me a tiny workshop with lathe and mill soon, so I can fabricate my own stuff. Building stuff for me is as funn as using them, and it is ahealthy change for me to get dirty in the shed, because besides industrial design and architecture which are my primary proffesion, this is my "office" lately, working as an offshore sailingboat captain

<a href="https://picasaweb.google.com/lh/photo/r7pX1Sg-GF4t5Wd6Mll1msp_n5aToeRrsFl6vL5HKcU?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-EzEazJ04SrU/UVxNGkUqV5I/AAAAAAAAA_I/EVaQCYRbxMg/s800/DSC06020.JPG" height="451" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/Va5PpSXp9rIZpbNogjMcVcp_n5aToeRrsFl6vL5HKcU?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-M25As633bQE/UVxNF7NykZI/AAAAAAAAA_E/_4ovvbxZ3Q8/s800/DSC05983.JPG" height="451" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/PuDeLcYP5Pq8aecjDBN3R8p_n5aToeRrsFl6vL5HKcU?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-UybyL8qr9VY/UVxNFRIWygI/AAAAAAAAA-8/Za8idQ4kFXQ/s800/DSC05987.JPG" height="800" width="451" /></a>

<a href="https://picasaweb.google.com/lh/photo/j4-jw6Jkymtd8mhXrigsFMp_n5aToeRrsFl6vL5HKcU?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-smC1UkNsINo/UVxNFcw8GcI/AAAAAAAAA_M/ZhQHoJ5884c/s800/DSC05863.JPG" height="451" width="800" /></a>

Today I managed to spend couple of hours on the bike. First i started to sort out the footrest mounts and foot commands

<a href="https://picasaweb.google.com/lh/photo/RXM2zSrQdJHqq_tw9vN5KtLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-vBP2WVPQd4E/UayutBrdT5I/AAAAAAAABTg/cZOG4WwdR8c/s800/P6030011.JPG" height="600" width="800" /></a>

Upper one is a new one, zx6e and the lower one is from a zx6e, and together with couple modifications, they should do fine for my build

<a href="https://picasaweb.google.com/lh/photo/LssVG1sg0O1ucoRJ_MPrqNLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-yaSUFvxBtwE/UayutaDzv0I/AAAAAAAABTo/UizTSvj8NyQ/s800/P6030013.JPG" height="600" width="800" /></a>

first I had to cut down the old broken triangles

<a href="https://picasaweb.google.com/lh/photo/VhHVlazUrsNmIFlequkdn9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-7_6ZbT6NKz4/Uayu31XNpXI/AAAAAAAABUA/jpYfUFe0ATk/s800/P6030014.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/Dw4880bqf6PeFGVqExdintLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-5QalgLD22BE/Uayu3OCtGDI/AAAAAAAABT4/iBs8iEGqe5U/s800/P6030015.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/l4csf7hsSTENg1lXfT4kVdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-fNjbNuJWm78/Uayu3t-Ll1I/AAAAAAAABT8/7v7_GmKyVlc/s800/P6030016.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/hrM5cmKobMCCuywc3btG3tLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-SbPL19LQZfw/UayvD0IAvlI/AAAAAAAABUY/llU4EPSmPLA/s800/P6030017.JPG" height="800" width="600" /></a>

this is all that I need from the old triangles

<a href="https://picasaweb.google.com/lh/photo/C5fRM7hsYXkaFiZMgiTvg9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-Ln2pS8E9QVM/UayvCs5kS1I/AAAAAAAABUQ/XWfFiRcyPIY/s800/P6030018.JPG" height="600" width="800" /></a>

this peace of crap makes me vomit every time I look at it

<a href="https://picasaweb.google.com/lh/photo/oNG0lhqAjjB0tzwFUx-WSdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-5RyV_piPJBw/UayvBsF29hI/AAAAAAAABUM/pFHVT7RJRNU/s800/P6030019.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/6IqYegQHsjq7Ub8mzgoXwtLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-TrcmeQ18yvw/UayvKMF7UDI/AAAAAAAABUo/VDg9M-egWXc/s800/P6030020.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/jxeITZwjGat-LtThOi-otNLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-lLp2PV1tNpo/UayvJ3O83BI/AAAAAAAABUk/zXatIyvIS5o/s800/P6030021.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/FZt5JiK-tdTBSMNJ-WXt5dLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-fJlzPLjWlzQ/UayvLmucDxI/AAAAAAAABUw/C1rej1iqf0w/s800/P6030022.JPG" height="600" width="800" /></a>

Dissassembly and cleaning

<a href="https://picasaweb.google.com/lh/photo/a14sRkSYtj0NtlsMhBa20tLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-1-dyococbyw/UayvTHW4U1I/AAAAAAAABU4/rLac3_6q0Pk/s800/P6030023.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/W8FFmBB9_CB2H72QnPFuTtLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-AYNdkFBremM/Uayv-ityEgI/AAAAAAAABWE/bzJuSX3FRCM/s800/P6030024.JPG" height="600" width="800" /></a>

making a new thread

<a href="https://picasaweb.google.com/lh/photo/0Hph21yTYmMwW9ZiRmodEdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-sMxSOnbnZxk/UayvU5AShCI/AAAAAAAABVA/A06Ubre3trk/s800/P6030025.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/nABEw7Pza36_kiYZ8HRg8dLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-2Ahcy2J8RJU/UayvrsA9BpI/AAAAAAAABVg/0rkxAnhnhXM/s800/P6030029.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/ok4GUPJ27AfNabNq0YI-s9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-b2MXMJLbhOE/Uayvu7A-oZI/AAAAAAAABVo/dsOGy6Q6WBY/s800/P6030030.JPG" height="600" width="800" /></a>

started to cut them down to size

<a href="https://picasaweb.google.com/lh/photo/Jb59tcDSvRm1cRI4wbqIo9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-bzYkPrjw_NA/Uayv0lBsbWI/AAAAAAAABVw/oDQbI3aCUso/s800/P6030031.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/nqg0bJCu8IP4EW3m4BTyxtLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-JjvE03-GT90/Uayv4R6sHwI/AAAAAAAABV4/bw8_gK68_u8/s800/P6030032.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/XbBKFPEZCQPDEZONY44_T9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-nuzTRJ-EM9A/UaywATyNm2I/AAAAAAAABWI/JfAdNPo9DcY/s800/P6030033.JPG" height="800" width="600" /></a>

they seem even enough to me This is just a temporary solution, I allready started to design a new peace from scrap and will have it waterjetted soon

Cleaned it all up and started to combine good peaces from both sets

<a href="https://picasaweb.google.com/lh/photo/Q__l6funWkDgR-VirxVtrdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-Nln8sXMrXkg/UaywOdKB6RI/AAAAAAAABWo/ECwF2P_rIJQ/s800/P6030037.JPG" height="600" width="800" /></a>

the shiftrod is really heavily bent, so I had to do something about it

<a href="https://picasaweb.google.com/lh/photo/cquurjExaPjxtMBv7hgNV9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-3QrD88CCICw/UaywRJvVVrI/AAAAAAAABWw/-MwjgdZR-xo/s800/P6030038.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/ZUw7e3JbMt6ma4tjBT4rudLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-4OBxTpzv_d0/UaywS7FRtyI/AAAAAAAABW4/sk8cEDoje9g/s800/P6030039.JPG" height="600" width="800" /></a>

vice and heat gun and some rotation and leverage and voila

<a href="https://picasaweb.google.com/lh/photo/JzNGqmsSPetLRFKvNiQKAtLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-hvCc4qz98o8/UaywVw6nTDI/AAAAAAAABXA/A5ps1JZXb-s/s800/P6030040.JPG" height="600" width="800" /></a>

straight-ish shiftrod

<a href="https://picasaweb.google.com/lh/photo/-Ls8U6j0yAc2okxCUA7cH9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-QO9yCINJZIU/UaywY9rhSFI/AAAAAAAABXI/OJol4N9dn-M/s800/P6030041.JPG" height="600" width="800" /></a>

good enough for me

<a href="https://picasaweb.google.com/lh/photo/dI6mRjreO_8akwNF4IEW6tLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-ZkbHDCmrNTw/UaywbfhqoVI/AAAAAAAABXQ/uFvj0pEnRa0/s800/P6030042.JPG" height="600" width="800" /></a>

I played a bit with different parts and got a final assembly. I think that I will have to play a bit with the shift rod lenght, but it is a couple of minutes modification, will do it in the end, when I get my waterjetted parts done

<a href="https://picasaweb.google.com/lh/photo/ri8kCzVGaNRX-gjfWrVXDdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-JJqJ9oxvbIU/UaywgMvy-1I/AAAAAAAABXY/13nlOmW1vOo/s800/P6030043.JPG" height="600" width="800" /></a>

Test fitted it on the bike

<a href="https://picasaweb.google.com/lh/photo/9x_IDjKgOG8TjWTzuHyTj9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-OV-ior0YCWY/UaywjYh8I5I/AAAAAAAABXg/0FxarUu48S8/s800/P6030044.JPG" height="600" width="800" /></a>

it is really solid, but it looks like shit It will do for the next couple of weeks, but it is not staying on

<a href="https://picasaweb.google.com/lh/photo/dnUvVAEcc4AJU0FH0BhVHNLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-123nLz61TAQ/UaywlIHUqVI/AAAAAAAABXo/UtpewS7SyYs/s800/P6030045.JPG" height="600" width="800" /></a>

I also drilled couple more wholes through my upper tripple and through risers, so now it is much firmer and I feel good and know it will manage to take the stress

<a href="https://picasaweb.google.com/lh/photo/AsnKmevfOeue_SFz9mdAsNLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-VHRpTDGKlTU/UaywnOOl5RI/AAAAAAAABXw/ukdgiF0CAqA/s800/P6030046.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/OyGVo5h7_M4LzKrf-U_tDdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-KBluWbDUHUE/Uaywo_jHFII/AAAAAAAABX4/MYRK3xVb0Ww/s800/P6030047.JPG" height="600" width="800" /></a>

I had to modify couple of screws

<a href="https://picasaweb.google.com/lh/photo/PSD3_OZDg3KfOBuCXoFzkdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-mseLfKpICiA/Uayvhh4PBMI/AAAAAAAABVQ/6Il_VxV7sOA/s800/P6030027.JPG" height="800" width="600" /></a>

it is easy peasy with the lever big enough

<a href="https://picasaweb.google.com/lh/photo/PoA6BZj9alDPbMLPii0Q9NLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-L4lCCtkoY8I/UayvcjPwgnI/AAAAAAAABVI/zAWBr7OtoPQ/s800/P6030026.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/CD2vlEws_Fck4JI82tltIdLGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-mskGtJADLVc/UayvlHiWWpI/AAAAAAAABVY/s-bj-_lDAfI/s800/P6030028.JPG" height="600" width="800" /></a>

That is it for today, time to start drinking

i like where this is going. most of us learn by doing. you'll probably have to buy some original or aftermarket rearsets, but i like that you're trying things first. and on a budget.

Well, yes, I allready said it looks like crap, and I meant it I wouldn't feel comfortable driving around with that holding me on the bike I am having this adapter made, so I can keep my zx6e rearsets

<a href="https://picasaweb.google.com/lh/photo/9alJUkOO5PCnt9egwLUZVOA183Y-a-gNpyfTd0tLEiw?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-298nVwK3efc/Ua2s5HO9M6I/AAAAAAAABYU/ZPYji1WJ_W4/s800/rearset.jpg" height="421" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/_Zhe0Daw6yQpmOoPM-4rGOA183Y-a-gNpyfTd0tLEiw?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-htr-tvAnwMM/Ua2s5g2pLII/AAAAAAAABYY/QppHMoaIJMY/s800/rearset2.jpg" height="421" width="800" /></a>

This was a preliminary sketch

Really enjoying your build as I have a ZX6E! Nice to see this bike brought back to life!!!!

A few years back I bought a set of rear set brackets for my ZX6E so that I could customize the peg location. If your going to have adapters made, why not have them made with some adjustability?!?!

Something like this....


Cheers!!!

I really thought about adjustable rearsets, but it is making things more complicated to produce, and since I allready sent these to my friend who owns a metal fabrication company and is water jetting it for free, I will keep it simple and stupid But I allready have some plans to make few other custom parts in the near future, so maybe I revisit this part aswell.

I have so many work to do in my company at the moment so the bike build is going really slow, but I should finish all of the big projects in around 15 days so I will manage to finish the complete bike till the end of the month

How do you like your zx6e?

Love my ZX6E!!!

It does everything from track days to long distance touring with zero complaints!!!!

Look forward to seeing yours on the road!!!

Hey! How's that ZXD going?
We want to see some more pics!

Greetings and congrats for your project from Argentina!

Can't, wait to ride it, it has been to long

Thank you for the interest, I have been busy as hell lately so I didn't have much time for the bike, but in 5-10 days, all of my mayor projects will be finished so the bike is going to be road worthy till the end of the month

say hello to Argentina for me, can't wait to visit your country one of these days

Ok,

here are some things I managed to do on the bike ina break from work when I get a chance

I didn't like the way the rear fender and the licence plate look,
<a href="https://picasaweb.google.com/lh/photo/9x_IDjKgOG8TjWTzuHyTj9LGbxSOmgPzwKhFEmFBlY8?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-OV-ior0YCWY/UaywjYh8I5I/AAAAAAAABXg/0FxarUu48S8/s800/P6030044.JPG" height="600" width="800" /></a>

so i choped it off



made a line with the marker and chopped it of with an angle grinder





still to ugly





much better



I am quite happy with it

It was a nice and warm sunday, so after I finished all of my projects for today, I joined the lady who was working in the garden and fiddled around tha bike a bit

<a href="https://picasaweb.google.com/lh/photo/B1BAezL5sfPQhSN82u8_wVD8JWupE5GJ20_DWRFinTI?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-bOBJe02Js0E/Ub32TL7rEyI/AAAAAAAABfk/xpcqVybxcfc/s800/P6160028.JPG" height="800" width="600" /></a>

this is not the final handlebar but it is pretty close. This one is from yamaha xt 125, but it is to short for me, I need something with more rise

<a href="https://picasaweb.google.com/lh/photo/w_61nuIMnSsSOPvuIX-SoVD8JWupE5GJ20_DWRFinTI?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-n8Cjt7ae56Q/Ub32VHymMPI/AAAAAAAABbE/W2UFT9fgcRg/s800/P6160031.JPG" height="600" width="800" /></a>

<a href="https://picasaweb.google.com/lh/photo/gqoaIH_05qT3EFRsxpcqSVD8JWupE5GJ20_DWRFinTI?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-LQpMsTojKkE/Ub32W4X74FI/AAAAAAAABbU/fpocp9PshQI/s800/P6160032.JPG" height="600" width="800" /></a>

Damn sexy bike

<a href="https://picasaweb.google.com/lh/photo/GtXg7PETp8B0ecthDdt3iFD8JWupE5GJ20_DWRFinTI?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-SgWJxhuWMis/Ub32VszqwEI/AAAAAAAABbM/ofu9qywJaWg/s800/P6160033.JPG" height="600" width="800" /></a>