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Unconventional 95 zx6r

40K views 193 replies 29 participants last post by  Zx9rb2 
#1 ·
Hey guys,

Been part of the site since march and this is only my third post, so it's safe to say I've been lurking and working. I've had my build thread up on another site since I started and figured I'd would put it up here also so I could get ideas on where to take it next. It might take me a while to copy and paste so bear with me.

Hey guys,

as the title says this is going to be my first fighter and im sure its going to run me for a loop with how old it is. im learning a lot about it every day just by reading everything i can that you guys write day in and day out. so this is a thanx for all the help so-far and also for future help that im sure you will send my way.

so with all that out of the way heres a few specs about the bike and pics too!!

my bike:





its a 95 and was in ok condition, runs good (needs carb work), suspension is pretty solid yet and all the plastics were there (or so i thought).

after a bit of inspection i found that i was missing the upper faring stay, the front cowl was wasted and the lower farings were toasted from the exhaust.

so instead of paying a ton of money to put it back to stock beauty i desided to look around on the internet to see what could be done with it and thats where i found you guys. the bike now looks like this.



i was happy riding it just like that for the time being until the bug bit and i bought these:

2005 ZX10R forks and lower triple clamp. i think i got them for a steal at $100. from what ive read they will be a drop in affair, but if thats not true i know i can just swap steering stems and call it a day. i still need a top clamp, clip-ons, and front wheel and calipers to make it all work.

thats where the story goes south. came out the other morning to ride the bike to work and wouldnt you know it its on its side. guess i didnt have the stand all the way out and it fell over. broke a few things that i didnt want to have to replace.



thats obviously the generator cover and i was planning on just using something like liquid metal or JBweld to fix it till i could find a replacement but its beyond fixable so thats out the window.

i broke the left side rear set also but that was fixable. it looks like this.


im hoping that this stuff works as well as they say it does.



so thats where i sit at the moment. im looking at a few new headlight ideas, but they are being pushed back till i can get her riding again. im not sure what all im going to do with her just yet but im sure its going to be a never ending project.

any help, suggestions, criticism, or comments are more than welcome. ill update as things go. also if anyone has a generator cover for me id be happy to take it off your hands lol.
 
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#2 ·
as promised its time for some pics of the progress.

so this is where i started last night:


and after about an hour i was here:




i pulled the front axel with this contraption:


the lower triple fits almost perfect in the frame. all i need to do is figure out the whole bearing situation and ill be good to go.


heres a side by side of the old triple/bearings, and what the zx10 bearings look like. (completely different)



i talked to a friend today and hes going to help me find a set of cups and bearings to fit the zx6 tube with the zx10 triple. hopfully this will all be done with so i can ride again lol.

if anyone is interested i have a zx10 key, steering lock/ignition switch, and locking gas cap that i wont need. they are a matching set and are in pretty decent shape.
 
#3 ·
so its only a couple of days late but heres my updates.

new gen cover and gasket:


and installed:


once that was done a friend of mine encouraged me to tackle the carbs, the bike starts and idles fine but falls flat on its face above 4000 in third gear and does nothing at all in 4-6th gears. my guess is that either the carbs are horrible or the jets are bad. we will see this weekend.

went to remove the tank to find out that the PO took out the pet cock, and also ran a fuel pump that isnt right for the bike. only good thing was that the fuel lines were long enough to just turn the tank and prop it on the rear of the bike for now.



tank moved, air box off and carbs exposed. they really dont look too bad from what i can tell but i also dont know what im looking at to be honest lol.


i have a question for anyone in the "know"..... i think the evap/emissions stuff was removed, but something doesnt look right to me about this and my be a contirbuting factor for poor performance. heres what im talking about.


heres the stock carbs with the 2001 gsxr600 throttle bodies i have sitting in the garage. i put the carbs next to the gsxr motor just to see how far out the were and they dont even come close so for now ill just keep the carbs till i figure something out.


heres what the top of the carbs look like. ill have more detail about the clealiness of them tomorrow or sunday when i tare them down for cleaning.


top of motor without the carbs. the back sides of the valves look pretty clean so im hoping thats a good sign that the motor is ok.


next up on the list of things to do is:
1. clean the carbs and check the jets
2. put the stock front end on till the new bearings come in for the front end.
3. replace the old oil filter and do an oil change
4. ride it like i stole it!!!!!!!!!!!

im also debating on a few headlight ideas. any sugestions are more than welcome. till next time guys.
 
#4 ·
well heres some pics of the little bit of tinkering i did last night.

needed to remount my blinkers:



and heres the headlight i tore apart for the HID system. got really lucky that i didnt need a ballast for it.





the bracket that i have on there for the time being is just a temp. ill have to make a good one once i do the front end swap.

and here is what i did with the fuel vacuum hose from the carbs.

since the evap junk has been removed already i just used the inlet from there with another hose i had laying around the garage and voila!! this also is temp just to see if that solves my issues. if it helps ill get some proper hose and fittings to clean it up.

so back to the headlight issue. i really hope that the bike just needs to be running to get power to the headlight. if thats the case then I'm all good. we will see this afternoon once i get the carbs primed and start tuning the idle.

wish me luck guys, ill need it lol. after i get her running again ill have to tare into the harness again to fix the ground wire for the fuel pump. its literally fried from one end to the other. now that i put some thought to it I'll fix that first lol. then its the fuel leak and i should be done for a while.

thanx for the help.
 
#5 ·
SUCCESS!!!!!!!!!!!! the head light is now in working order.



with the success of the headlight i started thinking again and ran across this!!!!


going to try to graft this into the zx6r instead of paying for an aftermarket unit. shouldnt be too hard i think.



i think it looks loads better than the stock unit. what do you guys think?



i still need to tune the idle on the carbs but the bike starts and stays running on its own. i should have more this weekend. going to have my friend come by again and help me tune the idle and then take her for a test run to see if the issues are worked out.

oh and if anyone has a service manual for a 2001-2003 GSX-R 600 or 750 i need the wiring diagrams for the gauges. hoping to get that wired up asap!!! thanx for watching guys. until next time!!!
 
#6 ·
I've been busy today, got tired of not having anything to do on the bike so i DW'd today.










and this is the color I'm thinking of painting the bike. i haven't quite figured out what i want to paint tho. either the frame green and the tank, tail and wheels white..... or the opposite. what you guys think? the green will also have a bit brighter copper pearl in it than whats shown. i just loved the green when i saw it.
 
#7 ·
Ok so I got a little done yesterday with the frame. Still need to finish that up and get the swingarm done too.










 
#8 ·
#10 ·
Well some minor updates, I decided to start putting some of the bike back together.




I'm not sure I like the black and white, I love the white but I think it's just way too boring with the black, might start looking into a better color combo. Something that I can use with the white and I'll use gold for an accent color. That's something for later tho.

I also tried my bearings out for the zx10 forks. Tops fit perfect but the bottoms that were supposed to fit don't. The lower race is just a cunt hair too big. I'll have to do some searching and order a different set. So that means the ones I have are up for sale. Brand new set of all balls conical bearings for a zx10. Stock fitment. If you want them I'll sell them cheap.

Later guys!
 
#11 ·
So very minor update time, got a couple minor things painted up. Gas cap and axel adjusters to be exact.





Finished!


Didn't take pics of the adjusters but I took them apart and painted the end caps to match the swing arm. Slow and steady wins the race I guess lol. Still trying to figure out my front bearing issues yet. Once I do I'll have the front end on and ready for the wheels. Saving up for pc, going to change up the plan a bit and do black spokes with white barrels. What you think?
 
#12 ·
ok minor semi DW updates....... pics!!











so what you guys see there is the bike almost back on its own wheels. i had a major debachle with the front bearings. so much so, that i couldnt use any of the bearings that i had for the bike. made a few decisions and asked a friend to help me turn down a collar for the zx6 stem to fit in the zx10 lower triple. the only big issue was that the zx10 lower triple was fatter than the zx6 so we bored out the collar deep enough to move the stem up high enough to fit the stock zx6 bearings in the proper places. so that means problems solved. just need to get ahold of allballsracing.com again for a fresh set of bearings for the zx6.

i really need a damn laith and mill lol...... till next time guys!! cheers!
 
#14 ·
in the interest of build progress information....... PICS

this is what i had done yesterday for my triples....



you can just see the collar poking out above the surface


we had it turned just a C-hair larger than the old stem, and again another C-hair smaller than the zx6 stem.


and to solve the difference in lengths..... (the zx10 stem was about a 1/4 inch longer)


and this is the last step that needs work to finish the stem swap.... (prolly just going to get a custom upper made when i can afford it)


for anyone that may be worried, please be at ease.... the collar was milled with lips on both mating surfaces to replace the standard cir-clip that kawi uses. everything is completely solid and probably stronger now than before i started.

going to get the collar for the upper clamp turned down, and a fresh set of bearings from all balls, and then the bulk of the front is done. just need a zx10 axel and spacers, caliper bolts, and any set of 50mm clip-ons and ill be back on wheels once they get painted.

questions? comments? concerns? all welcome and wanted. thanks for looking guys.
 
#16 ·
got tired of looking at the bike again so i did a little work......

sanded the crap paint down to baby butt smooth, and then wet sanded smoother lol....

paint tomorrow night.......

cut the left side passenger peg mount off and sanded flush



dont know if the right will stay or go just yet.....


making room for this stuff.....


wheel needs to be less one tire and plus some powder coating......
 
#17 ·
Some parts have come in........


See you guys in a couple hours!!!

Half time update...........



Third quarter was a tough one, the sprockets just wouldn't lay down and give up, but in the end I pulled it out for a win.



And the new chain, rk520 conversion........



And the final score this evening.........





Alright all you photo chopping gurus, do what you can with the moch up pics. I need help deciding what to do with the paint. White, black, and gold. Personally I like the green but it's gotta go for now. Comments and haterade is more than welcome, it's wanted. Let me know what I need to do. Thanks.

Paul
 
#20 ·








Check it out!









Still needs a little work but I think it'll look pretty good for now. I might change it up a little and add a wind screen but I like it for now. How's it look to you guys?


I also found a guy to powder coat the wheels for me. Said $150 for the set. Might get the headlight brackets, brake rotors, and the triples powdered while I'm at it. I'll have to save up for that tho. We will see.
 
#22 ·
ok so in light of recent events ive found a few things laying around the garage that got me really thinking about the actual style of the build so far. basically there isnt anything "style" about it. it just looks out of place with the way it sits.

i found a few things in the garage this weekend while pulling together all the crap i need to get rid of (in the for sale section, link below). so what i found is a damn comfortable gsxr seat and a custom tail that i forgot i even bought. so im going to post a few pics and ideas, i would like for you guys to help me figure out which direction to go with it.

as she sits with the addition of the newish seat---


damn near perfect fit--


idea number one-- just a mini tail and single seat setup...




idea number two-- and i know this may piss a few people off, but i think bobbing the tail might make a little sense. it just seems to fit the bike better than having a tail.









so those are the ideas and im not set on anything yet. just want a few opinions other than mine alone to see what you guys think. the only thing i did actually set my mind on was white wheels. i painted the rear tonight and i think its going to look ok. kinda did a shitty job since i wasnt able to pull the tire from the rim before painting but the tires will need to be replaced soon anyway so ill spend some time cleaning them up and getting them powder coated when the time comes. thanks for the input guys. see you later.

Paul
 
#23 ·
And progress will be severly slowed for a little while....... I would like to introduce Isabelle Victoria Wolfgang. She was born 13 October 2011 around 12:20 am.







I will be around, but mostly trolling till the little one is a bit more situated.
 
#24 ·
Thanks bro! And I have a mini update of sorts, got a basic idea of what I want the arse end to look like.





I want to make it look a little different, but the side view is going to stay about the same. I will have to cut the stock subframe down quite a bit, but all the blue you see is going to be fiberglassed after I make a mold, and give it some shape to match the seat. The rails will be covered by one large piece of fiberglass. I'm hoping that it will clean everything up enough to not look like shit lol.
 
#26 ·
Just talked to pro-tek about a set of rearsets, going to get a set of their rearsets anodized black. Just gotta wait ti they send them out for anodizing. Said I can have them next week. Fingers crossed lol. Made up my mind to wait on the Cbr for a while till I get the zx6 finished. Everyone ive contacted about a motor for the Cbr keeps giving me the run around. Going to hunker down and get this girl done first. Gotta have a bike for next season so one at a time is my best bet I think. I'll have updates soon I think.

Going to get some parts from these guys, Fab Parts , the start working on my subframe. It's going bobber very soon. Hopefully I'll get this thing done before the end of winter.


Just went on a buying frenzy of sorts. picked up another set of zx10 front calipers, lines, and the radial master cylinder that I didn't have. Got a zx10 clutch perch for the ever so low price of $3.77 (shweet). And I also got a set of china made shorty levers all from eBay. I'm committed to getting this little girl up and running. Going to pay for my rear sets next week when they are available, and I'll start the gasket job on the motor this weekend. Going to paint the block and case covers black, and add gold anodized bolts for a little kick. Also going to get some subframe bungs ordered so I can do the chop ASAP. I'm motivated today guys!!!!
 
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