zzr600 project bike

[Simondo]

Well this thread hasn't been touched in years, and neither has my ZZR!! until today I've sold my R6, and the MT-09 is getting sold as well, which leaves me about a month and a bit to get my ZZR sorted and back on the road before the MT-09 goes if I want to have a bike to use..

I was a couple of years younger when I last worked on it, and I left it like this..



Which as you can see looks horrendous, now that I'm older and much much wiser I've seen the light... the new light..



And that one looks way better

Next to go on is a new exhaust, oil in and fresh coolant, etc and get the thing running properly, hopefully I wont have too much drama there

[Deleted]

The new light looks better George :-)

[Lee]

Good for you simon, I was chatting with someone today about you and you're doing the right thing.
We all like our bikes, but it's good to see that you have taken a look at life and prioritised.
You've still got a bike, ok it's a bit tatty but it's a bike.
Soon you will be ready to make a big step in life.
From here on in, it'll be possible to trade up for a couple of hundred quid every year or so until you are back on your feet.
I think you've made a very grown up decision and I doff my hat to you.

[Simondo]

I'm still going to the TT though Lee so I need the ZZR working and reliable by then, which is my challenge for the next few months

[Simondo]

Last night the exhaust and radiators went back on, tonight's jobs are to free the Pistons, fill the oil and coolant up and wire the headlight in

[Simondo]

Quick half hour today in the garage and bumped into a few problems, didn't get the oil or coolant in, however on the plus side I found that the connectors for the headlight were wired the same and had the same connector so it just plugs straight in, super bonus..

Biggest problem I have at the minute though is making the radiator fit properly, the picture below shows bits that are supposed to connect together



I've ordered a few connectors and 90 hose pieces that cost far too much money but the result will be spectacularly over engineered

Plenty to be doing while I'm waiting for stuff though, bodywork, clocks, electrics, carbs

[maverick]

Don't know if i've missed an episode but isn't that radiator upside down

[Simondo]

Look at the mounting point at the top, its definitely the right way up

[maverick]

I think you should have another look because definately look like its upside down, also it it fit before you removed it why wont it fit now.

I had the 600 a couple of years ago, it started out looking like a wreck but rebuilt it and it finished up looking not to bad

[Simondo]

Feb 21, 2015 20:14:29 GMT maverick said:

I think you should have another look because definately look like its upside down, also it it fit before you removed it why wont it fit now.

I had the 600 a couple of years ago, it started out looking like a wreck but rebuilt it and it finished up looking not to bad

It's definitely, definitely the right way up, the reason it doesn't fit properly is because I relocated the pressure cap and thermostat because I've done away with the front sub fairing, and moved the thermostat lower and further back so that it's out of the way of the fork and headlight assembly

[muzzasv]

it might be the right way up but are you sure its not back to front ?

[Milky C]

Feb 22, 2015 18:06:15 GMT muzzasv said:

it might be the right way up but are you sure its not back to front ?

Are you sure its not actually a pair of ice skates?

[zeddman]

This is where I got my free genuine manual www.pdfmotomanual.com/index.php?r=site/page&view=manuales&order=t&key=K&make=1815&lang=ENG

[Simondo]

Well I've had some parts delivered so it's time to crack on, Motorcool did a good job of the rear wheel so I've got that to assemble and fit, hoses have arrived to sort the cooling system out but I'm looking to relocate the overflow bottle from the back to just behind the radiator up at the front, I'm just not sure what effect this will have on the temperature the bike runs at

[Milky C]

Mar 11, 2015 7:35:30 GMT Simondo said:

Well I've had some parts delivered so it's time to crack on, Motorcool did a good job of the rear wheel so I've got that to assemble and fit, hoses have arrived to sort the cooling system out but I'm looking to relocate the overflow bottle from the back to just behind the radiator up at the front, I'm just not sure what effect this will have on the temperature the bike runs at

Should have very little if any mate, look at the race bikes that run them like that

[Simondo]

Feb 21, 2015 20:14:29 GMT maverick said:

I think you should have another look because definately look like its upside down, also it it fit before you removed it why wont it fit now.

I had the 600 a couple of years ago, it started out looking like a wreck but rebuilt it and it finished up looking not to bad

Guess what, you had good reason to believe I had the radiator on wrong because on the e model (the one you had) the hose point comes out of the back of the radiator at the top instead of the front.

The solution to my misalignment problem is to fit an e model radiator because then they will line up again since I moved the pressure cap, super bonus, I've ordered one and it will be here in the next week, nearly time to get it running

[Simondo]

Bikes coming along nicely

[Simondo]

Sorry to bring up this old crap over and over again but I thought I'd post an update since its been so long.

It's been a bit of a funny couple of years, with saving for and buying my first house, it feels like I've had a year off biking, and I've hated it, but that's another story.

Earlier this year I had been furiously working on the ZZR in an attempt to get it ready for this years TT, it didn't matter anyway because of the house I never went, but a couple of weeks after the TT was over I took the ZZR for an MOT, and it passed!

It wasn't without issues though, slight problem with the front brake, thought it was air in the system but turned out to be a warped disc, feel stupid that it ended up on the bike in the first place, but an easy fix since I had a spare.

The bike then ran like a bag of spanners for a bit, sometimes it would run on all 4 cylinders, sometimes on 3, took the carbs off, cleaned them, fitted them, better but still not right, took the carbs off, set the float heights, set the gaps, took off the idle jets again, cleaned them again, sorted, it ran so much better than I had hoped after that.

Then there was a problem with the electrics, not charging the battery properly, slowly got worse until I was having to bump start it all the time, took it off the road. Took way too long to fix and I missed out a lot this year because of it, anyway its running again, better than ever.



Having covered some ground on it now I know what I need to do this winter to make big improvements to the way it rides, I've already ordered a new shock for the back and some links to compensate for the lost ride height, but apparently the mod I'm making makes the ride so much better, should stop me from scraping the centre stand mid corner at least (not due to silly lean angles, just saggy suspension)

Then I'd like to put it back to a 4 into 2 exhaust system but this depends on Santa really, cos its quite expensive.

So that's it really, it's an ongoing project, one I'll probably never finish, or justify spending so much money on, but I'm so determined to polish this turd it WILL look like a diamond one day!

[nickw]

Well done so far Simon. Looking canny...

[ZX6-Chris]

looks good simon,. take alot of time and money to get it how you want it.