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Old 04-27-2012, 09:43 PM   #1 (permalink)
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Default LJ's fighter project

Ok so I've decided to go fighter with my 2006 ZZR600. Most of the work is pretty much done, but when I dive into a project I like to post up what I'm doing to hopefully help others out before they attempt the same and/or to inspire them too.

Let's start with a mods/parts list:

Suspension and braking:

--front: 07/08 ZX6R forks & lower tree, CBR monoblocks & radial master, braided lines, 07/08 ZX6R rotors
--rear: 05/06 ZX6R swingarm, 09 ZX6R shock, stock links, ZZR rear master, braided line, 07/08 ZX6R caliper, 05+ ZX6R rotor
--wheels: 05/06 ZX6R

Frame and engine: 2006 ZZR600 "J" model, stock jetting with K&N air filter, stock engine with 43,000 miles, 07/08 ZX6R subframe and tail

Exhaust: 03/04 ZX6R header, 07/08 mid pipe and muffler (CF Yoshimura RS-5), and a custom link pipe to join the mid pipe and header.

Other modifications:

--ASV C5 brake and clutch levers
--engine covers sprayed gloss black with Rustoleum engine enamel
--frame and swingarm sprayed low-gloss black with Duplicolor engine enamel
--Protaper handlebars and risers
--HoHey top triple tree
--05/06 ZX6R stock sprockets 520 conversion (+3 teeth in rear compared to stock ZZR sprockets)
--Buell projector headlights (still trying to decide if they'll stay or be replaced)
--Third Eye bar end mirror (may buy a second one for the right side also)
--other random bits and pieces
--had to remove my 06/07 ZX10R OEM Ohlins damper due to the HoHey top tree, so I'm thinking I'll relocate it to the frame mount on the left side with a home made bracket.

I recently crashed my bike, but rebuilt my fairings and everything for reinstallation. I got the idea to go fighter, debated it for a while, got some inspiration, then went for it. I wanted the more upright seating, naked look, and overall different look than you see everyone else riding day in and day out. So love it or hate it, IDGAF.

Here she is. If you have any constructive criticism or suggestions, feel free to post them up. If you're gonna hate, then GTFO please.



Not sure if I'll keep the Protaper thingy on the bars or not.



The HoHey top tree is pretty cool. It allows you to use either bars or clip-ons. If you want to run clip-ons you install these aluminum plugs in place of the risers and install the clip-ons on top of the tree (recessed in that area so you don't have to remove the tree to swap over).



Still need to decide on my headlights, but this works for now. I wired them into my stock plug for the original headlights. I need to remove the rest of the upper fairing stay and make a bracket to move the gauges and headlights in closer for a better look.

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Last edited by LarryJ; 05-01-2012 at 02:48 AM.
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Old 04-27-2012, 10:06 PM   #2 (permalink)
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Hey, so did you have to get longer cables or will the stock ones work?
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Old 04-27-2012, 11:24 PM   #3 (permalink)
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well, a set of zx14 rotors would be a sweet trick too...I have a set just waiting for my lazy ass to install them.

drastic change but very nice none the less!
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Old 04-28-2012, 12:04 AM   #4 (permalink)
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Thanks, Jake.

Kent, the cables just barely fit with a wee bit of extra play when turning left and right. I thought I might have to cut off the ignition mount and relocate the ignition elsewhere in order to make room, but it worked out. I'll have to post up a closer pic. Brake lines were the only things I could not reroute or otherwise make work. $70 for longer replacements will be overnight delivery Monday after they're put together. Assuming no rain I'll be able to ride Tuesday. She's only been sitting for three days anyways. Lol.

I'm considering changing over to a more Kawasaki shade of lime green. Any thoughts on green radiator hoses, brake res caps, and a few other spots?
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Old 04-28-2012, 06:59 PM   #5 (permalink)
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Cool shit bro. I think a Kawi Green with green hoses, etc would look great! I think it would go along great with the fighter look.
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Old 04-28-2012, 08:14 PM   #6 (permalink)
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Thanks, Cason. I think I may pull the trigger on the hoses. The only problem is it'll drive me to repaint the bike so everything matches correctly. I need to get a hold of my powder coater and see if he can get Kawi green for my wheels. I'm betting he can.
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Old 04-28-2012, 08:25 PM   #7 (permalink)
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Here are some pictures of the cables. You can see there is very little room for movement, but the clutch cable does have some play and there's no issues with clutch operation. The throttle cables however are being a whore. They're too tight for my liking. In the second pic you'll see the cables run over the left air duct on my air box, so I'm going to pull the tank, trim the lip on the air box, and see if I can get a little more play in the cables. If not, then I'll entertain running the throttle cables between the tank and top of the frame. We'll see.
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LJ's fighter project-imageuploadedbymotorcycle1335659000.996951.jpg   LJ's fighter project-imageuploadedbymotorcycle1335659056.561973.jpg  
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Old 04-28-2012, 10:16 PM   #8 (permalink)
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Being a whore? Sounds like they are being a virgin How much did your powder coater charge you to do your wheels? Can they do lip strips? I need to find a local place to do mine, but have NO idea what to expect price wise.
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Old 04-29-2012, 02:29 AM   #9 (permalink)
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Love a good fighter build.. I thought about doing the same to my g1..
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Old 04-29-2012, 03:56 AM   #10 (permalink)
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cut that exhaust down!! at least so the tip lines up even with the seat, or even shorter
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