2002 A1P slow project - Page 2 - ZX6R Forum
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post #16 of 37 Old 03-30-2017, 12:31 AM
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Quote:
Originally Posted by RJ2112 View Post
The most important question... the one not answered as of yet -- WTF happened? Where is the oil leak? Has it already been fixed?
He mentioned that it was an oil spot on the floor from when he did the oil change.
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post #17 of 37 Old 03-30-2017, 01:01 AM Thread Starter
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What happened

Quote:
Originally Posted by RJ2112 View Post
The most important question... the one not answered as of yet -- WTF happened? Where is the oil leak? Has it already been fixed?
I thought I gave a quick summary but I'll post a more detailed time line of events.

* Pulled the bike out the garage and started it to warm it up (old choke bike remember)
* As I was closing up the garage I noticed a patch of oil on the back tyre.
* Wiped the oil off and thought that will be fine I will just take it really easy until its had time to scrub off.
* house is on the corner of a T junction on a slope so I usually just roll out to the junction in neutral or with the clutch in
* went to pull out and turn left (we drive on the left btw)
* at that point the back tyre spooled up, burnt off the oil & heat up the tyre. the tyre bit in an high sided me off the other side all at walking pace and within about 6 feet.
* cut the engine, lifted the bike and pulled it to the side of the road.
* reopened the garage door and rolled the bike the 20ish feet back into it.
* went back out and picked up my broken bit of fairing (which will prove vital at the body shop)
* took off my gear, jumped in the car and went to work.

the oil is from the old carpet covering the garage floor, I must've spilled oil during the oil change and its soaked into the carpet and obviously oil doesn't really dry in.
its not leaking from the bike, thankfully.

Rider is ok minus a sore shoulder, which I'm sure is just impact damage and not a broken collar bone.
luckily years of being a black belt in judo natural reflex was to roll out the landing which i'm sure has paid into the fact i'm not as injured. well that and really good protective equipment.

the strip down begins on Sunday, the fairings will be passed to the body shop and I will start stripping the broken bits and give a full health check on the bike but I'm sure it will be a couple months before its back on the road which is a shame as I'm going to miss some good weather and a few events which I was really looking forward to. Always next year I guess.
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post #18 of 37 Old 04-03-2017, 03:46 AM Thread Starter
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Update 02/04/17

So work began on stripping & inspecting the bike on Sunday.

Dropped off the fairings at the body shop, still awaiting a full quote for the work and a rough timeline however I'm in no real rush.
* R/S fairing
* Nose Cone
* Ram Air intake
* Headlight (having a lug welding back on)

I've also now sorted a full parts list:
* New Crash Bungs
* Bolt Kit
* Short Levers
* R/S Ram Air fairing trim
* Mirrors (going for a brand new replica pair so they look the same rather than an old and new)

potentially: nose cone/clock bracket (going to try and straighten the old one)

so this is how she currently sits.
silver lining as because she is so stripped down I've been able to clean and inspect every nook and cranny.

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post #19 of 37 Old 04-06-2017, 08:16 AM Thread Starter
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Parts update

So new parts are arriving.

New nose cone bracket. Old one was really badly bent and the shape was to complex to reform it, so ordered a brand new replica at a cost of £28 guaranteed OEM fit.
If anyone with a J model wants to ditch the birdcage it's definitely worth considering.



Also my new shorties arrived.
£45 ebay specials and tbh I'm impressed with the quality, especially for the price. Would I preferred mad scientist ones? Definitely! But by the time the were shipped to the UK the costs would've mounted and ive a long list of parts and repairs still to pay for.
Here they are compared to the stock items.



More updates once these are fitted.
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post #20 of 37 Old 04-13-2017, 02:23 AM Thread Starter
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minor update:

was comparing the new and old bracket last night as I was going to fire an extra layer of paint onto the bracket. well the legs on the new bracket are about an inch too long.

the bracket is a rep but guarantees 100% OEM and does reference the the Kawasaki part number so dont know if its just a faulty one, contacted the seller just awaiting a reply.

OEM bracket on the right (obviously the right leg is bent from the accident)



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post #21 of 37 Old 04-13-2017, 07:51 AM Thread Starter
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Well 2 updates in quick succession.

Shortys on
With the aid of my garage assistant.





Dents on the tank pulled.
From 2 dents to one tiny one, not perfect but not bad at all. Chipped the laquer and a bit of the decal but nothing a touch up pen wont solve.

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post #22 of 37 Old 04-20-2017, 12:15 PM Thread Starter
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Very minor update:

Bracket has been sent back. now just awaiting my refund and replacement from a different company.

Hopefully arrives soon and I can fit it and remount the clocks atleast.
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post #23 of 37 Old 05-01-2017, 01:11 PM Thread Starter
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UPDATE!

New bracket arrived, was the right size and is now fitted. Happy days!!!
(Didn't get any pictures sadly, next time)

So front indicators are now sorted, some of the finest 2500grit wet and dry. Polished out the marks on them. Some bumper restorer and they look like new.


While I have been waiting on the fairings I haven't been sitting with a thumb up my arse. The dent of the tank has been popped out which is a result.

While the bike is naked I have been cleaning/detailing every inch i can get at.
Could probably eat your dinner off it, not bad for a 15yr old bike.






My brother is currently painting my cockpit trims gloss black and i may remove the carbon heel plates, rub them down and fire on a fresh coat of laquer.
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post #24 of 37 Old 05-05-2017, 11:09 AM Thread Starter
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My brother is currently working wonders on my dash trim that was scratched in the crash.

Rubbed down and in primer.


1st coat of gloss black


2nd coat of gloss black


2 coats of clear will be fired on beginning of next week.

Slowly coming together
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post #25 of 37 Old 05-05-2017, 12:42 PM
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Rab.... nice work!
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post #26 of 37 Old 05-11-2017, 01:10 PM Thread Starter
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UPDATE:

so trim pieces have had there final coat of clear, well pleased with the results.
I've to give them a week before I polish them and put on a couple layers of wax.



Carbon fibre heel plates from my gilles rearsets were rubbed down and gave a blast of clear, still another to go but so far they look good.



So last bits are falling into place, ordering up a new stainless steel fairing bolt kit soon. New pair of mirrors will be ordered aswell, only need one but I would rather a matched pair so i dont have one new one and one old.
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post #27 of 37 Old 05-12-2017, 08:20 AM Thread Starter
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Quote:
Originally Posted by Stiggy View Post
Found this on the Kawasaki Forum and thought it would prove useful on here.

Now for a little more info regarding other bikes.
-05-10 ZX6R Wheels are all the same
-98-04 ZX6R Rear Wheels the same
-05-10 ZX6R Front Rotors are all the same
-98-10 ZX6R Rear Rotors are all the same size and bolt pattern, they just went to a "Wave" rotor in 2005
-98-10 ZX6R Front Sprockets are the same CHECK PITCH 2003 went to 520!
-98-10 ZX6R Sprockets all have the same bolt pattern, 2003 they went to 520 from 525
-98-04 ZX6R Mirrors are the same stud spacing
-05-10 ZX6R Mirrors have the same stud spacing
-05-08 ZX6R Swingarms are the same, in 07 they changed the look slightly, but still the same bolt spacing and sizing.
-03-08 ZX6R Clip-ons are all 50MM and work with each other.
-03-06 ZX6R Top Triple Clamps are the same just look different
-03-08 ZX6R Forks the same dimensions are the same, just 03/04 had smaller rotors so the caliper mounts were 10MM shorter.
-03-10 ZX6R Calipers all bolt up, 03-06 ZX6R Exactly the same 07-10 ZX6R went to Nissins which are a much better caliper.
-98-10 ZX6R Bar Ends all the same
-00-10 ZX6R Gas Caps interchangeable
-06-10 ZX10R Front Wheel same as 05+ ZX6R
-04-10 ZX10R Rotors the same as 05+ ZX6R
-98-03 ZX9R Rear Rotor same as the ZX10R/ZX6R
-98-04 ZX6R Passenger Pegs the same
-05-10 ZX6R Passenger pegs the same
-98-10 ZX6R and ZX10R Rear Calipers are all the same
-98-10 ZX6R Cush Drives are the same piece
-98/99 ZX9R Front Rotors are he same as he "G" and "J" and ZZR600
If I am reading this correctly, I might fit the newer model mirrors as they look alot cleaner and simpler.

if so I might be upgrading. does anyone have pictures of a J/A model with B model mirrors?
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post #28 of 37 Old 05-24-2017, 01:10 PM Thread Starter
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So wee update:

Crash mushrooms arrived


Carbon heel plates are done after the 2nd coat of clear.
Carbon weave is obviously worn but i think they came up great, a quick polish and couple coats of wax and they will look spot on.


2003 ZX6RR mirrors are here.
Vast improvement on the old 2002 mirrors on the left.


Job for the weekend is to clean up the exhaust and give the bike a good going over.

Update from the bodyshop is mid june, has been so busy the guy hasn't been able to start them. So I'm further away than I would have wanted.
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Last edited by Rab; 05-24-2017 at 01:51 PM.
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post #29 of 37 Old 05-26-2017, 02:54 PM Thread Starter
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Update:

With everything apart from the fairings sitting ready to go I thought I would make use of the good weather do do some final prep for when the fairings finally arrive.

Main job was to clean up the exhaust.
See this on YouTube, harpic black power bleach. Amazing results with little efforts.

Before.


Afters:



Then continued cleaning the rest of the bike.....

Refitted the carbon heel plates, the painted intake trims & the intake grill.




And one with the very very dirt dog wagon in the background.
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post #30 of 37 Old 05-26-2017, 03:00 PM
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Very nice bike @Rab
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