Project Sharky's ZXR shed

Tried to finish the panels off a few times now,but weather or extra busy neighbours have held things up on the days I wanted to paint. Also,as I sprayed the pieces I came to the conclusion I was not going to have enough basecoat to finish the whole fairing, & I need some for the rear cowl I will make aswell. Left a side panel for now but painted up rest & also done the ugly scratched mirrors with the last of the paint, need more paint now though.

 

Finally got some more paint & finished the last panel, gave them all a buff,wash & polish. Also done a few finishing jobs like finding all fairing mounts,rubbers & screws, cutting some stainless tank hoses & starting on the rear cowl. Also noticed some yellowing on the headlight, on closer inspection something didn't look right. In the end I had to use some thinners & elbow grease to remove what was either epoxy or clearcoat Whatever it was done a decent job of hiding whatever happened to the lense,except the yellowing, but a sand & polish worked better. Fitted on the fairings for only the second time since I have had the bike,to see how it all looks, to check the inner fairing piece lined up & also the tank hose length. Not far off now.

 

Not one of mine, all mine are around the Gold Coast area unfortunately & unbeknownst to me were sold with a lifetime of free labour & servicing Had a few more electrical gremlins show themselves that I never knew about,until the bike was running with everything together. The high beam & passing button now work, but i had to pull apart the loom to sort out the starter lockout/ neutral & sidestand switch problem. The bike came without the starter lockout switch,it just had two wires bridged which allows it to operate normally, except, it will start without clutch in gear. I replaced the switch thinking that was all it needed, but the bike would stall letting the clutch out in gear, after much checking this & that the neutral light died completely, replaced the neutral switch with a spare & everything works perfect. If the switch was broken,I can see how it would still go to ground on the shift drum, but how it was affecting the fusebox diode circuit to act like a sidestand switch problem. The broken switch Couldnt find any swivel ratchet bits so I had to drain the rad fluid & remove the water/oil pump to access the neutral switch The eventual carnage Fitted some cheap small wattage led globes to see if they outperformed the halogen standard globes. Look at this on eBay http://www.ebay.com.au/itm/113354980541 There h4 globes so I got the metal not plastic base, so I could use the tabs for the mod trick. Lowbeam Highbeam

 

All good on the hoses @maelstrom one project at a time, I'm sure you have many projects on the go.

 

Have spent 3 days working on the cowl on & off, and the last 2 days itching from the foam & fibreglass, probably not the best idea to sand fibreglass in boardshorts & no shirt . Everytime I make a cowl I try something different, not sure about the top of this one yet, still might change it up.

 

Like the first pic? They already have one that shape, it's called a rear seat, + theres no therapy in that.

 

Yes I should do an A model original cowl for sure

 

Finished the cowl long ago now, havnt brought myself to fill the lovely new tank yet & go for a spin up & down the road. I have basically thrown a blanket over it & moved onto other endeavours, one of which involved me helping a young guy get there zxr running & registered, but lost all my bike tools in the process after changing a flat tyre in darkness & leaving the tools on the side of the road, rotor puller,carb sync, torque wrench, valve spring compressor,comp guages & all the best other little bits & pieces all gone .
Also needed to seriously get onto my own bike & do the head gasket(light bubble in rad) & fork seals, replace the rocker cover gasket & camshaft cover gaskets with spares(leaking). I need new brake pads & cam chain tensioner. I even been waiting 18 months to put a lite tek kit in the carbs & remove the air leak, I ended up dropping the motor out for ease & it also needed a good clean,its never had the full treatment like my other girls get, so I went even better this time. A few downs was the wear on the clutch, will need a replacement soon, & not having my valve spring compressor to pull the head apart, no metal pipe the right size to make one either.





Cant believe the carbs have finally been done.
I will be cleaning motors this way from now on with threebond. Just gave the rocker cover a light sand & polish by hand.






Bought a carb sync near new off Fbook locally for 20$, the guy couldnt use it because the needles were not in even. Bought it & synced them up while I was doing the carbs,i used the t'pieces & the air compressor with spray gun regulator to sync them evenly at different ranges.