Kawasaki ZX6D - ZZR600D build thread

Discussion in 'Some Assembly Required' started by aposaric, Jan 27, 2012.

  1. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    I am still waiting for my order of original kawasaki parts from Japan that I need to finish the engine and start it up, so during the weekend I sorted the rear suspension and the givi lugage finally

    <a href="https://picasaweb.google.com/lh/photo/91pqGPmTOX7r-X5cpMnnqMPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-iAjrl7ZVXKk/Udqijj8wmcI/AAAAAAAACXU/R7MsQ1qitfU/s800/IMG_2503.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/QiCDfzOON5eeQjDoxGuMx8PMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-wih5SLhhhck/UdqimhzPGsI/AAAAAAAACX0/jACV_V-Q1HA/s800/IMG_2507.JPG" height="533" width="800" /></a>

    I is still sitting very low at the rear end, so I need even shorter dogbones

    Rear lugage cariers mockup

    <a href="https://picasaweb.google.com/lh/photo/8DY7PuEHi5O4nWkw9ATF3cPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-8-dHGlPRdCg/UdqincMv_lI/AAAAAAAACX8/M6AQUSZQN8M/s800/IMG_2508.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/36gXYNIDjSLOC6nA0xp5osPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-7lJpdeQEJCQ/UdqioYCHcdI/AAAAAAAACYI/nEOCwQl0nYs/s800/IMG_2509.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/lmWx7f72Sulz78qvTBYkbsPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-Zx3DTfZ_7j4/UdqipJoIPjI/AAAAAAAACYM/76vtDEIQwR4/s800/IMG_2510.JPG" height="533" width="800" /></a>

    Looking sexy :-)

    <a href="https://picasaweb.google.com/lh/photo/yKiql1gwR3z2OOVr-3Ss6MPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-Q88IB7dzJgY/UdqistY9_ZI/AAAAAAAACYs/s1VY4Y_6JQQ/s800/IMG_2514.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/L8hBCJzFUe3xxK2lX-TzkMPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-6y5VRPwMyYc/UdqitVIL7WI/AAAAAAAACY0/Xq0k2bIIchg/s800/IMG_2515.JPG" height="533" width="800" /></a>

    To close

    <a href="https://picasaweb.google.com/lh/photo/P8Q7rcskI95HCY7PccWjlMPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-u9TqGEMEhns/UdqiuR_SxyI/AAAAAAAACY8/rvmb6jo8odg/s800/IMG_2516.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/orore25Jmi_Nw261VrOPOMPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-QjmPxwJOr_M/UdqixBmksBI/AAAAAAAACZU/UMScpj4N6vY/s800/IMG_2519.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/8RvthfY-hOaKDWsFhUHbu8PMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-hkmKTNjMu9s/UdqiyGSF1fI/AAAAAAAACZc/l4iJngtGyyQ/s800/IMG_2520.JPG" height="800" width="533" /></a>

    There needs to be at least 3-5 cm more of gight at the back

    <a href="https://picasaweb.google.com/lh/photo/fUCf1y9bGCWqR1zv1M02-MPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh6.googleusercontent.com/-vPepFT16atA/UdqizPZTaqI/AAAAAAAACZk/f1t7EAmStLs/s800/IMG_2521.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/cFhBUJRgnk_FDHpSsanWtsPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-iXmeNR8AYbM/Udqi0KMuLwI/AAAAAAAACZs/wAph9kj8iRc/s800/IMG_2522.JPG" height="533" width="800" /></a>

    This is going to be a setup without some sort of a woman on the back seat :-)

    <a href="https://picasaweb.google.com/lh/photo/RFiXYtPCUMr39CbSanm5TcPMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-HogH3dsFh4Y/Udqi08Qp3xI/AAAAAAAACZ0/XoXlhTZlJVo/s800/IMG_2523.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/zF1wggWlrNnfKl6WQw6t08PMYwyHfOz4y_Zekwm3mrk?feat=embedwebsite"><img src="https://lh5.googleusercontent.com/-lolK7x2Eelc/Udqi2HxSIDI/AAAAAAAACZ8/uF__fsauXSg/s800/IMG_2524.JPG" height="533" width="800" /></a>

    When I lower the front a bit and highten the rear, It is going to get a bit nicer stance. I still don't know what the ride will be, so there will be a lot of tinkering untill I get it right. Trial and eror :-)

    :freaky
  2. BigPigDaddy

    BigPigDaddy ADV Dreamin'

    Joined:
    Jun 26, 2013
    Oddometer:
    20
    Location:
    Orygun
    Great job! :clap

    I am amazed at how resourceful you are. Can't wait to see pics of you blasting down a gravel road soon.
  3. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Thanks :-) I am using what I can get my hands on, so there is a lot of improvisation but I am having a great fun :freaky
  4. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Finally, today I got my parts that I ordered couple of weeks ago, all of the gaskets and the seals and the filters that I needed to finish the engine overhaul. I also ordered a rear caliper repair kit, new seals and new front 16 tooth sprocket, so it will lower a gearing a bit comparing to the stock 17T one, which is good, because with the naked setup of the bike, I really doubt that I will need the 150+ mph performance from this bike. 100 mph will be more than enough, so I will also change the rear one when the time comes to something a bit bigger to get more midrange useability

    <a href="https://picasaweb.google.com/lh/photo/y0xH7czceIRqpZ4noB2W3GB2Pe5y9pA_WloXHz72pCE?feat=embedwebsite"><img src="https://lh3.googleusercontent.com/-Q6qqdDVaZ78/UdxDSQG14fI/AAAAAAAACac/rk7LRWMxtqY/s800/IMG_0003.JPG" height="533" width="800" /></a>

    <a href="https://picasaweb.google.com/lh/photo/W0ILdOBRWwlU3vG4Gflq8mB2Pe5y9pA_WloXHz72pCE?feat=embedwebsite"><img src="https://lh4.googleusercontent.com/-cuzZtGIptXo/UdxDSrTNbJI/AAAAAAAACag/8_szzg0gZHU/s800/IMG_0004.JPG" height="533" width="800" /></a>

    I have so much busines s lately which is good from one perspective, but I just can't find spare time to work on the bike. So between clients comming in my office and all of the meetings, I sneak into the back garden and work on the bike :-) I hope that I will manage to free up a whole day tomorow to finish the bike and start it up finally :-)
  5. L.B.S.

    L.B.S. Long timer

    Joined:
    Feb 26, 2010
    Oddometer:
    1,507
    *cough* *cough*

    :ear :lurk

    :D
  6. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Hy, long time no see :-) Unfortunately, I had really tough few months. My father past away so I had to spend a lot of time at my mothers house, I also broke up with my girlfriend so there is a lot of partying and sailing involved and not too much work on the bike has been done.

    I hope that I will get my boost soon so I can finish this bike. I rode the strom durring the summer, so I haven't been completely bikeless :-)

    I will post updates as something new is done

    to do list:


    1. finish the wiring
    2. rear blinkers
    3. gass, clutch and choke wires
    4. air the brakes
    5. fill it up with gass
    6. MOT
    7. DONE :-)
    There is not much work left, which is kinda nice :clap


    Thank you for the interest :freaky
  7. duxrneet

    duxrneet Been here awhile

    Joined:
    Jul 20, 2009
    Oddometer:
    675
    Location:
    Melbourne, AUS
    8. Do a run at a drag strip
    9. List 0-100km times!
  8. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Ha ha ha, I am not sure that is going to happen :-) I think 0-100 (kilometers) is somewhere around 3 seconds and 402 meters is around 11 seconds but this is not what this bike is really about :-) It is a cheap beater that will hopefully never get stolen :-)
  9. L.B.S.

    L.B.S. Long timer

    Joined:
    Feb 26, 2010
    Oddometer:
    1,507
    Awe, sorry to hear, mate :cry My Dad just passed away not too long ago as well, so I feel for you.

    I wish you and your family best thoughts.

    It will be a great relief to get your bike up and going again, I bet! :thumb

    Looking forward to seeing the completion :D
  10. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Hy, thank you :-) Well, yes, it was quite of a shock with my fathers death, but there is nothing to do about it, but I was feeling quite sad for the last couple of weeks so the bike is going to wait until I am feeling better ;-)

    :freaky
  11. Dilligaf0220

    Dilligaf0220 Miserablist

    Joined:
    Dec 23, 2007
    Oddometer:
    4,532
    Location:
    Armpit Of Canuckistan
    Did you sort the dogbones?
    A common trick was to swap in ZX11 dogbones, got the rear up around 20mm over stock. It is a unique size shock & linkage, which 20yrs later makes backyard improvements a bit of a PITA.
  12. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Yes, I found a dude who owns a wrecked ZZR 1100 so he is going to sell me his dogbones. It is not so hard to source the parts for this bike here, they were really popular here in Europe, so there is tons of parts available, and there is still a lot of aftermarket companies that produce pretty much every replacement part that I needed so far.

    Thanks for the tip :-) :freaky
  13. Dilligaf0220

    Dilligaf0220 Miserablist

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    How beat up was your stock fairing stay? I need (another) one. :1drink
    The D model isn't exactly rare here, but not exactly common either.
  14. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Fairing stay was beaten to the bone :-) I wanted to use it in reverse position as an engine guard bracket holder, so it is going to get put in a good use :-)

    ZX6D and E were one of the most popular bikes in Europe, they were sold here from 1990. till 2007. so they are really widely available here, and when I tried to find a good replacement for a worn up Versys, zx6d and cbr900 were only two options that had a bullet proof reputation of 200.000+ kilometers of average use for a sub 2.000 euro bikes. I needed something cheap, reliable and bullet proof for my base bike :-) And I did a lot of research and most of the remote countries in Europe ( Norway, Russia, Ukraine, Turkey ) have a solid stock of the used bikes, so it is not hard to get replacement parts if I get stuck anywhere with broken bits
  15. Dilligaf0220

    Dilligaf0220 Miserablist

    Joined:
    Dec 23, 2007
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    Location:
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    Other than clutches (2), a new stator, and a R/R, I haven't had to replace any hard parts in almost 190,000km (150,000km put on by me in the last five years). Even the valves only needed adjusting once.

    I have gone through three fairing stays though, but I do enough highway & riding in the rain that I like the stock fairing. Even though now mine is held together by Plastex & fiberglass tape.

    I have been known to do stupid things with a fully faired sporty bike, like ride 100km of rough gravel roads then down an offroad track to find the perfect camping spot. :1drink
  16. flumpmaster

    flumpmaster Adventurer

    Joined:
    Sep 26, 2011
    Oddometer:
    11
    Location:
    League City, Texas
    I've enjoyed reading your build thread. I was sorry to read your sad news and hope you cheer up soon - I look forward to seeing pictures of the finished bike.

    I noticed in one picture it looks like you have used nyloc style nuts on the exhaust manifold studs. I don't think they are going to like the 'warm weather' when you start the engine....

    [​IMG]
  17. 16VGTIDave

    16VGTIDave blame Reaver...

    Joined:
    Nov 4, 2012
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    599
    Location:
    Drumbo, Ontario, Canada
    I have to agree. Nylock nuts are not for high temp use. The nylon inserts will melt or burn. Also, those nuts aren't "in-safety" as they say in the aviation world. The threads on the studs have to stick out of the nuts for the locking to occur. There are self locking nuts available for use in high temp areas, check with you local hardware suppliers.
  18. Frank from Quebec

    Frank from Quebec Adventurer

    Joined:
    Feb 1, 2013
    Oddometer:
    14
    I see this as single use EGT :D
    How satisfying it will be look at these melt evenly on startup :happay
  19. aposaric

    aposaric Garden mechanic ;-)

    Joined:
    Jul 6, 2007
    Oddometer:
    270
    Location:
    Zagreb, Croatia
    Hy folks, thanks for the safety tip :-) I haven't really thought about it that way because old nuts were all fucked up and twisted so I threw them away. I will definitely replace this with something more suitable.

    I am sorry that I stopped updating, I had to take over my late fathers company so I have been busy running my company and my fathers company as well and all the spare time I have left I spend with my mother. I will be back on my feet shortly.

    Cheers :freaky
  20. L.B.S.

    L.B.S. Long timer

    Joined:
    Feb 26, 2010
    Oddometer:
    1,507
    Looking forward to seeing updates :D