My ZXR 400 L4 UK-spec

Been crashed, crashed, rebuilt and crashed, now undergoing its (hopefully) last rebuild back to near-mint, which with 50,000 miles on the clock is no easy feat

Just replaced front fork seal, front and rear rubber, rear brake disk and cleaned up the calipers (rebuilt them a few years ago and still all good).



i am on the management committee for an upcoming motorshow next week, so i was hoping to have the fairings back for them...but thats not gonna happen, so for the moment this is how it stands, it fires up first time and is not bad cosmetically, will look a lot better with the new front fairings, the main points to sort out now are:

1. rear shock is shagged, needs replacing.
2. needs new suspension bushes along with the rear shock.
3. powdercoat the frame/swingarm/torque arm dark silver.
4. powdercoat the wheels.
5. new chain/sprockets.
6. new front disks and pads all round.

 

the white thing in the picture is my lightweight track zxr400 l3 uk-spec, with l2 higher-lifting cams, no starter motor, running total loss. out of shot is my street-fightered fzr1000 exup-r, and then the orange bits of fairing are my 70cc racing scooter, currently undergoing a full rebuild, new sport barrel, new crank, all new bearings, pro-sport exhaust, currently porting the cases/gaskets and flowing the intake and exhaust a bit more...looking for 12bhp at the rear wheel, and maybe a top speed of 80mph, i killed the last one doing 70mph and that only had 8bhp, this one should be a bit quicker and has a custom made 1/8 turn throttle, so its basically on or off

 

been making the scooter loom, have gone from this:


this:


and this:


to a spanking shiney new loom



all in original colours, will be PVC tubed and wrapped, then connectors added and fitted to a soon-to-be powdercoated frame...

not bad for ~4 hours work

 

in the past ive always made looms on the bike, or when ive been moving electrics around into non standard positions...but i have to say, im liking the idea of a wiring jig from now on, made it really easy to do, easy to check errors, and made splicing wires hastle free (you will notice ive spaced out my internal wire-splice junctions... ), im well happy with it, ordered thin pvc tubing and a few connector blocks last night, should be here in a few days, and ive removed two non-standard connector blocks (one a really compact 4-connector block, and the other a wide flat 4-connector block) and i hope to either source a new replacement, or re-use these old ones, they look ok, and the plastic holders look ok, but if i can buy them new each for a quid a piece ill do that rather that re-use...doesnt make sense as im building a new loom from scratch.

if i have time ill unsolder all the internal connections from the clocks etc, and remake those into new sub-looms...but for the moment i can tackle them some other day, and they are all easy enough to get to at a later date, not like the loom that gets threaded through the frame of the bike.

need to dissassemble the rest of the scooter (forks, shock, headstock, ancillary's and some plastics) and send it for blasting and then black powdercoat then build it back up again...