2003 ZX6R Resurrection - ZX6R Forum
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post #1 of 21 Old 12-28-2016, 06:03 AM Thread Starter
Squid
 
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I Ride: 2003 ZX6R
2003 ZX6R Resurrection

Ok, so it's not that bad.

I posted this up in the new section, but thought I'd go ahead and post progress stuff here for kicks. It has about 32k miles on it. The previous owner bought it at something like 3k miles, so he put most of the mileage on there and I think all he did was change oil and tires (tires look almost new). I got into it a little bit last night to do the oil, oil filter, coolant change and air filter. I found the factory air filter. And the oil filter didn't look that new either, nor did the oil, but at least it had oil in it. It's in decent enough shape mechanically. It started and idled with zero issue when the guy pulled it out of the garage, so that's a good sign. I rode it 50 miles or so to get it home, but it's parked until I can replace the chain and sprockets. I'll have to get pictures of that. Worst I've ever seen without actually missing teeth.

Other plans are to check the valves (never been done, I'm sure) and replace the leaking valve cover gasket and swap out the plugs at that point. The oil sump pan is also leaking at the gasket, but I'll probably get that on the next oil change. Going to fab up a small fender eliminator and ditch the signals for now (not required in Texas). I will probably end up with an integrated tail light and flush mounts on the front. We'll see. Also have a double bubble windscreen coming. Ditching the mirrors in favor of a left side bar end.

The fairings are all there, but the right side is damaged from at least one low speed drop which also scuffed the upper. The left lower is missing a big chunk near the front. The undertail fairing is quite scuffed from some rubbing of some sort, and the main tail fairing is broken at the clips under the front seat. Seriously considering dropping the money on an aftermarket fairing kit, but it's ok for the time being. The tank is nearly perfect.

Anyhow, I'll try to add some pics as I go.
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post #2 of 21 Old 12-28-2016, 11:25 AM
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Nice find. What kind of riding you planning on doing with it?
Where you at in Texas?
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post #3 of 21 Old 12-28-2016, 02:19 PM
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Neat! Where in Texas are you at?
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post #4 of 21 Old 12-30-2016, 07:47 AM Thread Starter
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I Ride: 2003 ZX6R
I'm north of DFW in Denton.

This bike is quite different for me in a lot of ways. I used to be a motorcycle commuter for over a decade, so any time I worked on my motorcycle, it was overnight in a parking lot and HAD to work the next morning. This one I have parked in my garage (moved into this house about a year and a half ago) and it's just in pieces.

One of things the owner included in the sale were a replacement ignition switch because the one on the bike was finnicky and your had to go to the full lock past ignition and then flick it just so back to off. Imagine my surprise when I saw that it was mounted with bolts where the head sheared off.

So last night I took the motorcycle down to almost nothing, only to realize there is no good angle to get a drill there without removing the top yoke. So a trip to the shop for the right massive socket for the steering nut and I got it off. I tried using a bolt removal tool and had no luck. Then I said "eff it" and grabbed a 3/8' drill bit and just took the heads off and let the vice grips grab the exposed part of the bolts. Job done.

I also had to replace the right side footpeg and the bracket for that. Jeez, that pedal return spring is tough. And so much red loctite on the footpeg bolt.

Coming along.
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post #5 of 21 Old 12-30-2016, 06:32 PM Thread Starter
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I Ride: 2003 ZX6R
Ugh. Stupid PO's.

The shift elbow is absolutely knackered. Just noticed it in the garage now. I mean, it shifted fine on the way home, but I did have one false neutral that had me worried. But between the absolutely dismal state of the rear sprocket and the state of the shift elbow, I'm surprised it shifted as well as it did.

I thought I was going to have it road ready by Tuesday night, but now it looks as if I'll be waiting until I get the shift elbow in via ebay. Probably end of next week at best.

Things done so far:

-Switched out ignition switch and right side peg bracket (both supplied by PO who had them on hand) as well as a cheap replacement peg on the right
-Air Filter (the stock one was still there at 32k miles. I read the date stamp and it matched the VIN)
-Oil and filter
-Coolant
-Plugs
-Cheap levers via amazon (the right was bent from a previous spill)
-Working on freeing up the frozen choke cable

Still to do (for minimum road worthiness):
-Windscreen on the way (stock one is old and yellowed)
-Swap shift elbow
-Chain and Sprockets (on the way)
-Install fabbed up fender eliminator
-Left hand bar end mirror

I Also need to do the valves and valve cover gasket in the near future (at least before spring), but the above will get me rolling and inspected/registered

Down the line stuff:
-Oil sump gasket
-Fork Rebuild
-Brakes are good, but when the time comes, a full brake rebuild (calipers and master cylinders) and SS lines

Also, how noisy are the throttle bodies supposed to be on start up? I thought that was the fuel pump priming, but I was testing the ignition with the tank and airbox off when I noticed it was the throttle bodies. Any videos of start up? What would a bad TB motor sound like?
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post #6 of 21 Old 01-04-2017, 09:31 AM Thread Starter
Squid
 
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Ok, not sure who's paying attention, but it's nice to have a list of what I've done so I can double check myself.

So I did the chain and sprockets on Monday. The front sprocket was factory. The rear was aftermarket and severely done for. Two of the sprocket nuts were stripped enough that I had to tap the socket on with a hammer to make sure it seated. Bought replacements for those with my order. The rear axle nut was so loose I'm horrified I rode it 50 miles. It was maybe hand tight. Tensioner bolts had nuts that were nearly stripped, but still useable. The old chain might have been factory, but had some rust on the inside of the rollers and was pretty stiff.

SO nice to have done it myself, set the chain tension, properly installed the rivet master link, and properly torqued everything down.

Also got on my fabbed up license plate bracket and managed to machine down the old mirror mounts to serve as block off plates.

I put everything back together again, except for the lower fairings. It fired right up again, but the idle is off just a touch even after a new air filter and plugs. It's smooth, but has random "peaks" if that makes any sense. I've still yet to do the valves or sync the throttle bodies. I'm also thinking some injector cleaner couldn't hurt. It jumps right up with a little bit of throttle, so no hesitation or bogging. All in all, it runs really well and could run better still.

Now I'm just waiting on the stinking shift elbow. I ordered it last Friday night, just before what ended up being everyone's 3-day weekend. I didn't even see movement on the package until yesterday and USPS is saying it will probably be Saturday. Oh well. It decided to be winter here again and will be cold until next week any way. Just anxious to get it inspected and registered.


To be 100% honest, I'm now a little scared that the transmission might have issues. Even if it weren't deliberately abused, the condition of the chain and shift elbow indicate the final drive was i such poor shape, it could have affected the transmission. I'll feel better when I can run it with a sorted final drive and see how it performs.

EDIT: Oh and I did find a few videos of startups and the TB noise is fairly normal from what I saw. Just noisier than I expected.
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post #7 of 21 Old 01-05-2017, 08:03 AM Thread Starter
Squid
 
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I Ride: 2003 ZX6R
Ok, here's a couple of quick pics. Fender eliminator with two cheap amazon bolt lights. They work ok, but the wires are tiny and awful to work with. I think it was like 10 bucks for the pair, though.

Also, a shot of the mirror mounts machined down to serve as mirror block off plates. I might finish them up a little more and powder coat them later, but this works for now.
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post #8 of 21 Old 01-05-2017, 12:07 PM
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Nice bike man, I have a B1H also with 31,700km on it (19,700 miles) and I love it. Good luck with the resurrection, I look forward to following your progress!
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post #9 of 21 Old 01-09-2017, 07:22 AM Thread Starter
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So I was waiting on the shift elbow, but it looks like the USPS hub in Fort Worth is a little hungover from the holidays still. I've got two packages coming and both sat in FW for a couple of days according to the tracking.

But yesterday I said screw it, threw on the old shift elbow and took the bike for a spin. Holy cow, does this thing pull starting at about 8k. I kept it below 6k on the ride home because I was scared I would shear off what was left of the sprocket teeth if I pushed it. I wasn't even trying and pulled onto the freeway at over 110 mph. Just unbelievable power when it hits the powerband.

Like I said in my new user post, I've had 3 motorcycles before and was a motorcycle commuter for over a decade, but this thing makes me feel like I have to learn how to ride a motorcycle all over again.

Anyway, it looks like my stuff should get here tonight, but either way I plan on getting it inspected tomorrow and getting things titled, registered, etc. Looking forward to warmer days.
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post #10 of 21 Old 01-09-2017, 07:24 AM Thread Starter
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Oh, I forgot: It idles like crap when cold. It did well when I first picked it up, but it was slightly warmer and I wonder if the clogged factory filter almost made the mix just rich enough to run. It has a Yoshimura slip on and a K&N air filter now, so I might have to spring for a power commander down the line. But first, I need to run some seafoam and see if that clears up the injectors, followed by a valve adjustment and TB sync.
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post #11 of 21 Old 01-11-2017, 09:06 PM Thread Starter
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Good news: got everything rolling and went out to get it inspected Tuesday. Now all I need to be legal is to stand in line for registration.

Bad News: I just found out why the old sprocket was so trashed as well as why the rear axle nut was hand tight when I touched it.

Whatever jackass last took this wheel fully apart did NOT put the spacer between the sprocket carrier and the hub bearing. So the force of the outside spacer was just pushing inward on the sprocket carrier bearing. It totally destroyed itself. I didn't catch it because I wasn't paying enough attention and I never removed the carrier to replace the sprocket. I still should have noticed...

So now I've got bearings on order and a replacement spacer coming my way via snail mail from GA. Probably another week at best.
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post #12 of 21 Old 01-12-2017, 04:03 AM
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great project, loving the updates.

doing similar stuff to restore my 2002, however the previous owner had took good care on my baby.

look forward to more updates, but green ones are faster lol.
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post #13 of 21 Old 01-12-2017, 07:15 PM Thread Starter
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And now begins the portion of the project wherein we are now over budget, but things continue to go wrong and the poor owner begins his descent into madness.


Well, I ordered the rear wheel bearing kit, and decided to spring for brake pads as well as the rear were rather low. Now I'm thinking I should go ahead and flush the rear brake. And really, why not the front? But it would be silly to do so without going ahead and doing the front pads as well.

It seems that the bearing kit does not include a carrier bearing, so I went ahead and picked one up at a bearing specialty shop. Not cheap, but about the price of an OEM+shipping from anywhere else.

I get one rear bearing and the carrier bearing out. Suddenly, it occurs to me that something isn't matching up. Check the bearing kit... they're too small. Look it up online. It's a FRONT bearing kit. Amazon lists it as a rear because it fits SOME rear wheels, but only indicate that it fits my ZX6R, which it technically does. Oh well, I probably needed front bearings and I wanted to do the brakes anyway...

It looks like the proper bearing kit actually DOES have the carrier bearing. But I already opened the other one and uglied up the bag/box. Don't think they'll take that back...

Wait, how did a bearing replacement turn into an additional 200+ dollar project?
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post #14 of 21 Old 01-13-2017, 02:18 AM
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Motorbike thats why
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post #15 of 21 Old 01-15-2017, 11:34 PM
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Dude. I won't lie, I'm biased. I have a silver 04. That bike has been the most reliable tank of a bike I've owned/ridden (and that's been quite a few). A few notes of possible encouragement:

1. The ig switch issue is common on this year. I've replaced several. Many others here have as well.

2. I'd pull out the fuel pump and clean the fuel filter. While it isn't supposed to be done, you can easily disassemble it with some finesse and a flat head screwdriver. Just be very careful not to break the white brackets.

3. While I'm sure you didn't budget for much, once you get this bike tip top you'll still have spent less than you would have on a brand new bike.

I have cabinets full of enough bits to build up an entire spare 6R. If you need anything, feel free to send me an email. I may be willing to part with it.

However, if you get sick of your build, and decide to cut your losses... I'm in the market for a titled frame.
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