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Old 05-22-2013, 11:19 AM   #46
aposaric OP
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Location: Zagreb, Croatia
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Well, I am not sure wether anybody is reading this or not, since there are no comments on this build, but I am going to keep on posting here untill the bike is finished :-)

I managed to get it out of the house today, and have put it back behind the house so I can start it up and drive it around my garden to test it before puting it on the road :-)







































Here is the reason I have put it outside ;-) this is my summer man-cave :-)



Here it is tucked in for the night :-)

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Old 05-24-2013, 04:56 AM   #47
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Here is the parts list that I need to pick up one of theese days, and the bike will be finally finished :-)



I had all of the brake lines steel braided, and am waiting for the bigger handlebars to measure for the new gass and choke lines

cheers

andrija
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Old 05-24-2013, 05:11 AM   #48
nuggets
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Nice work.
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Old 05-25-2013, 09:10 AM   #49
aposaric OP
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Thanks, I am slow, but I am getting there
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Old 05-26-2013, 11:00 AM   #50
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new footrests

One of the biggest issues that I had with original bike were also the footrest "triangles". They were all bent up and wellded pretty poorly so they had to go. I managed to find very simmilar footrests, they are from a newer zx6e model, and are in mint condition. They just need cleaning and are going to be anodized black. I thought about sourcing the originals but what the heck, since I am scraping this bike together with parts from ten different motorcycles and modifying them, this is just another peaco of the puzzle. I am going to fabricate a bracket to fit them on the bike, because this is not a bolt on swap.



I think the difference is more then obvious :-)











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Old 05-28-2013, 02:38 AM   #51
duxrneet
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Looks better than new.
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Old 06-02-2013, 01:38 PM   #52
aposaric OP
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Thanks, I am doing my best with very limited skills and even more limited tools :-)
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Old 06-02-2013, 01:52 PM   #53
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Well, today was a very productive day, i spent my whole afternoon in the shed, working on a bike

first, I started with the bar risers, they are originaly from a kawasaki '87. gpz 600, and I chopped the original mounting holes, because I can't fit them on a zx7r upper tripple clamp, so I made new mounting points with receses for the nut heads



















I brushed everything down, so it can be anodized



I like the look of raw aluminium :-)
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Old 06-02-2013, 02:12 PM   #54
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After that I started to clean and polish my nuts



After that I started to assemble the front brakes





I polished all of the nuts, bleed nipples and banjo bolts







It looks like it came from the factory, I am very pleased :-)

Here is my little polishing station :_)



brake nuts before cleaning



polished one on the left



and assembled brakes :-)



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Old 06-02-2013, 02:20 PM   #55
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After brakes, I started to overhaul the water components, water pump and thermostat assembly









thermostat







And after cleaning and resealing :-)





Ready for paint and fittment

Waterpump







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Old 06-02-2013, 02:23 PM   #56
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after the pump and thermostat, I had fun with ugly water distribution lines:

before



after :-)



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Old 06-02-2013, 02:29 PM   #57
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After that I went to handle the brake lines distribution, and test the steel braided brake lines



It is going to look awesome all in shiny steel

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Old 06-02-2013, 02:32 PM   #58
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I bought nice aluminium grips, so I mounted the gas one:



cut the old one



and mounted the new one:

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Old 06-02-2013, 02:37 PM   #59
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Clutch and brake levers were bent a bit, but not beyond repair :-)

So, I took a vise, and a heat gun and started to slowly form the levers, milimeter by milimeter, shifting leverage and momentum and heat across different sections, and in 10 minutes, voila, all the levers are as good as new :-)











They will be powdercoated
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Old 06-02-2013, 02:41 PM   #60
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After that I opened the brake fluid reservoir, had some problem with the seized screws, but some hammering, vise and wd40 and it is opened



it was all filled with gunk





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