2002 A1P slow project - ZX6R Forum
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post #1 of 22 Old 01-11-2017, 01:40 AM Thread Starter
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2002 A1P slow project

I thought I should move the info from my intro thread into its proper section.

This project is going to be slow and it will be me trying my best to get my 15yr old ninja back to better than show room standard with a few discreet improvements on the way. most of which will be done over the following winters.
So I will start the story from the beginning. (copied mostly from my intro thread)

After having my license almost 2yr I have since been desperately trying to convince my wife to let me get a motorbike of my own (a ninja obviously) & on the night of my 30th birthday party she surprised me with this....

2002 A1P ZX6-R 636
at 15year old she had just ticked over 31k miles, with alot of documented history. Almost like she went into my head and picked my perfect bike.

SPEC AT THE TIME:
* Micron carbon fibre exhaust (loud! )
* Pyramid rear hugger
* Gilles titanium rear sets
* Goodridge braided line to the rear
* double bubble screen

Some pictures from the morning after the party:




as requested some pics from my travels. these were a couple months ago, the bikes now tucked up in the garage hiding from the terrible Scottish winter

Castle Douglas with the boys.




Scottish highlands & Loch Lomond



(when your girl has a drinking problem but you love her anyway) NEVER RIDE PAST A FUEL STOP AS THERE AINT MANY WITHIN MOTORBIKE TANK RANGE UP THIS WAY



Run down following the west coast

Girvan Harbour




Ayr Beach





LET THE MODIFICATIONS BEGIN!!!!

This winter however the list of jobs was minor: new paddock bobbins from Oxford have been fitted which makes getting the rear wheel off the ground far easier.

Oil change with upgraded K&N oil filter, HEL lines all round, brake fluid flush with new DOT 4 & change to clear indicators rather than the bright orange. So Santa arrived with some motorbike related gifts.

one of which was an Optimate 3 battery trickle charger. No pictures of this but for those of us who have to tuck the bikes up for the winter it is an awesome bit of kit, comes with the quick connector so just fit it to the terminals and the plug sits under the pillion seat for easy charging.

the pyramid hugger has since been removed and awaiting my new chain gaurd, bolts, sump plug & gasket to be delivered to my local Kawasaki dealer.

Spot the difference Clear vs Orange



R&G bar ends


ordered an OEM replacement front brake line kit from HEL (carbon effect, chrome banjo's) however they contacted me saying they had problems with the OEM kitting fitting properly and asked if i could send my stock lines down to be used to develop an updated kit for the future. so the lines are currently with HEL and the new ones should hopefully arrive for the weekend for me to fit (pics to follow)

so anyone ordering an OEM replacement lines for J1-A1P models from HEL in the future your welcome

I also removed the tank pad & stickers the previous owner fitted. looks so much cleaner now, I will fit a new less fussy tank pad before I ride it.


with the stickers removed the paint work was looking a bit sorry for itself and being a bright color there was a noticeable difference in shade from were the stickers had been. so a mate came round and gave the bike a good machine polish to remove the color difference, some small scratches and paint swirls. then 2 coats of Meguirs finest wax.

the pictures don't do it just as its in a dull garage and it was raining outside so didn't want to take it out, however i promise to upload some when the weather clears hopefully again a beautiful backdrop of Scottish landscape but for now.



Hopefully the next update will be with the HEL lines fitted
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post #2 of 22 Old 01-11-2017, 02:51 AM
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Looks great !
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post #3 of 22 Old 01-18-2017, 01:58 PM Thread Starter
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Delivery from HEL performance, first class product and service

So that looks like my Sunday is sorted then.

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post #4 of 22 Old 01-19-2017, 03:53 PM
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She's looking great!!!
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post #5 of 22 Old 01-23-2017, 08:19 AM Thread Starter
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Busy day on Sunday fitting my parts to the A1P.

had a nightmare pulling off the left hand fairing as the previous owner had rounded one of the screws, so that required drilling the head off before I could begin and then once it was off the back of it and the engine was covered in dirt and grime so that had to be cleaned before I could even start the fun stuff.

so new HEL carbon brake lines front and rear fitted and new Castrol React brake fluid flushed through. best thing I've done, the feel through the lever and pedal is exceptional. The old fluid that came out, especially the rear was horrible and full of air so braking performance will be massively superior to before.

also fitted my new chain guard from Kawasaki.
new K&N oil filter fitted and a fresh sump full of Castrol Power Race, stuff that came out wasn't great and even just revving in the garage the bike sounds smoother/sweeter and more free revving.

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post #6 of 22 Old 01-23-2017, 08:45 AM
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"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #7 of 22 Old 03-10-2017, 02:23 AM Thread Starter
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Well got the bike out for its first run of 2017.





favorite pic of the run
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post #8 of 22 Old 03-28-2017, 02:01 AM Thread Starter
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Unhappy Came off!!!

DISASTER!!!!

had an accident on my Ninja yesterday morning which resulted in a low speed high side.

Full story:
pulled the bike out the garage and let it warm up and as I was closing the door I noticed a patch of oil on my back tyre (discovered a small oil stain on the garage floor carpet which is from the oil change over the winter) which i obvious rolled the bike over. wiped the tyre and thought that will be ok aslong as i take it easy it will scrub off.
rolled the bike out the drive to the T junction to turn left pulled out gently and lit up the back wheel then that obviously scrubed off the oil, heated up the tyre and it bit in and spat me off the other side.

all at walking speed

luckily I walked away with only a sore shoulder, this is why i never squid & my gear is barely marked which again is lucky.

at the end of the day it was my own fault. I may not have been riding like a dick (have a witness who agrees) but I made the decision seeing the oil that I would be ok and if we go further back it was probably me that spilled the oil and didnt notice/clean it up properly. so no body else to blame and I will take this expensive lesson and remember this for the future.

so the bike......



baring in mind i just rolled it straight back into the garage and took this quick pic so i could have an idea of the damage and jump into the car to go to work. So Ive not been back to properly assess the damage as yet.

but going by the pics and my memory I require at the moment...

* R/S fairing
* Nose Cone
* Brake Lever
* R/S mirror
* very small Dent pulled out the tank
* new bar end
* R/S crash mushroom

but until I pull off the fairings and get a proper look this list will probably grow. Im waiting on a fairing repair company to get back to me and Ive priced up a full set of replica fairings in the factory colour and graphics as an alternative depending whats better value.
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post #9 of 22 Old 03-28-2017, 02:45 AM
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So sorry to see this.... glad for your gear and good health.

An oil leak did the same to me, but I had almost made it to work.... 30 miles from home.

I hope your missus understands......I'd imagine she will..

"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #10 of 22 Old 03-29-2017, 01:24 AM Thread Starter
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The missus was mad but glad I was OK, she was as gutted about it as me because the bike holds sentimental value to both of us.

So went over to begin assessing the damage, again wont make a full assessment until I start stripping it down on Sunday.

Parts list so far.
(going down the break and up rate route)

body shop: been in contact with the fairing repair company, because I had the frame of mind to pick up all the small shards of plastics so I have no missing pieces it should all be repairable and redone in factory colours and graphics.

* Dent Removal on tank (might be able to do this myself I am borrowing a dent removal tool)
* R/S fairing
* Nose Cone
* Ram Air Duct

Fixings:

* Crash Bungs
* Fairing bolt kit (thinking going down the pro bolt route)

Bars:

* R/S clip on (maybe, don't know if its just moved or bent, R&G bar end might have saved it)
* Brake lever (was wanting a upgraded set anyway was thinking shorty's but I think I'll stick with standard length)
* Bar ends (R&G bar ends done there job, if I can get the plastic inserts that would be ideal but I might be able to get the machinist in the work to make me new ones on the lathe)
* R/S mirror
* Clock/fairing bracket (gonna try and straighten this out)

Exhaust:

* I'm hoping I can strip this apart and re-skin the carbon and machine the end or have a new one machined and I'll flip the bracket so the scuffs are on the inside.







Last edited by Rab; 03-29-2017 at 01:26 AM.
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post #11 of 22 Old 03-29-2017, 05:38 AM
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ouch, glad you are ok, bike can be fixed.
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post #12 of 22 Old 03-29-2017, 06:26 AM
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Sad to see the damage, glad the physical outcome for the rider was so minimal. All of that is repairable; the only question is at what price point.

There comes a point where that's not the most practical answer, and it's really an emotional decision rather than a logical one. I'd be in the camp of make it right no matter the cost, simply because of the sentiment. For me, it would be more a matter of keeping my loving spouse happy as she has been so supportive of my hobby.

If she said 'we have to buy you a new bike' I'd roll with that, too.....
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"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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post #13 of 22 Old 03-29-2017, 07:44 AM Thread Starter
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Quote:
Originally Posted by RJ2112 View Post
Sad to see the damage, glad the physical outcome for the rider was so minimal. All of that is repairable; the only question is at what price point.

There comes a point where that's not the most practical answer, and it's really an emotional decision rather than a logical one. I'd be in the camp of make it right no matter the cost, simply because of the sentiment. For me, it would be more a matter of keeping my loving spouse happy as she has been so supportive of my hobby.

If she said 'we have to buy you a new bike' I'd roll with that, too.....
It's defo a whatever the cost, even if it takes a long time.

not including the bodywork, worst case for the hardware etc is £220 at the moment which isn't a big deal, although its money I didn't want to have to put out. Best case its about £120 if my R/S clip on is ok, I can machine up new bar end inserts & straighten out the clock/nose cone bracket.

as for the bodywork I wont know til Sunday but fingers crossed it wont break the bank. other options include Chinese replica fairings which come in at £420 for a full set in the factory colours and graphics but I don't want to go down that route as I've heard poor things.

looks like my slow project has took a more intensive turn......
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post #14 of 22 Old 03-29-2017, 09:29 AM
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Glad you are okay, man!
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post #15 of 22 Old 03-29-2017, 09:34 AM
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The most important question... the one not answered as of yet -- WTF happened? Where is the oil leak? Has it already been fixed?
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"There's this adage that we have 2 ears and one mouth so we should listen twice as much as we talk. Unfortunately with the Internet people have taken this old adage and turned it around. They have two eyes and 10 fingers so they think they need to post 5 times as much as they read. And since they have 10 fingers and one brain, they only have to think 10% of the time! "
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