'89/'93 Ninja 600R revival - KawiForums - Kawasaki Motorcycle Forums
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post #1 of 8 (permalink) Old 10-27-2014, 06:35 PM Thread Starter
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'89/'93 Ninja 600R revival

Howdy fellas!
Bought a couple project bikes a few weeks ago for a real deal! I payed $200 for both bikes, titles, and manual. They've been sitting for roughly 10 years.
Bike #1:
-1989 zx600 (ninja 600) with clean title
-blown suspension front and rear
-stock airbox, carbs, and exhaust
-damaged plastics
-seized brakes
-dirty and rusty but structurally sound
-briefly ran on straight ether into the airbox

Bike #2:
-1993 zx600 (ninja 600) with clean title
-stripped of all plasics, airbox, seats, and some electronics
-molested exhaust and main harness
-brakes and rear suspension still salvagable
-donor bike only (for now)

So I've got these two bikes that I will turn into a single restored (mechanically) bike something along the lines of a street fighter with no plastics. I've already done a full clean and rebuild on one of the carb racks and had the '89 running prime. After doing that to make sure it's worth my time, I've started the strip down. The '89 will be completely broken down. The frame will be shaved, cleaned, and painted. The stock '89 exhaust will be cleaned and refinished for the final product. The head will be coming off of the '89 for a full cleaning and tuning. The airbox will be replaced by pods and a breather, the pods most likely being on custom stacks (great success with this on other projects). The front and rear suspension from the '93 will be rebuilt for the final bike. The gauge cluster from the '89 is fully operational so I'll probably hide that behind a custom headlight and small cowl. The brakes and swingarm from the '93 will replace the '89 as well. The final bike will be relatively minimal with nearly all unnecessary pieces removed. The tank will be modified from the '89.

I'll post pictures later tonight and continue to update with pictures as often as I can, this classic column on the forum needs some more excitement and I know you all love pics so thats what you'll get! Just be patient
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post #2 of 8 (permalink) Old 10-27-2014, 08:08 PM Thread Starter
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pics!
I'll get more next time im in the shop, these are from day 1.
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post #3 of 8 (permalink) Old 12-06-2014, 06:01 PM Thread Starter
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sorry for the lack of pics, have been away from the garage for too long. Will be back at the bike in a few weeks over holiday break. I have the carbs with me though and I'm prepping them for the new setup: uni pods and open pipes with custom baffles. I'm planning on starting with 1 up on the pilots, 2 up on the mains, and a slight shim on the needle. Thoughts?

Last time I was in the shop, I was just striping the donor to figure out what I have to work with as far as spare parts are concerned.
Other goodies: new coolant lines, ducati monster integrated tail light, fork seals on the way

Question: In the back of the tank, right under where the seat will sit, there is a single nipple out of the tank. Pretty sure thats a breather but I just wanted to check because there was nothing hooked up to it when i picked it all up.
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post #4 of 8 (permalink) Old 12-10-2014, 03:24 PM
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The nipple on the back of the tank is only a vent. My 1989 has it as well.
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post #5 of 8 (permalink) Old 12-15-2014, 01:46 PM Thread Starter
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Thanks daring, figured thats all it could be for.

Got a good bit done this weekend. Swapped the prime suspension from the 93 onto the 89, as well as the swingarm and rear wheel. Rear now feels nice and firm and is looking a bit cleaner. Front suspension is for next weekend, new seals and oil are on the way. I started to modify the beat up exhaust and working on where to hang it up after removing the passenger pegs and peg mounting tabs. Moving along slowly
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post #6 of 8 (permalink) Old 01-04-2015, 08:29 PM Thread Starter
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Big progress over the past couple of weeks.
-full fork rebuild up front with new oil and seals
-cleaned tank and started patching dents and holes
-mounted carbs and new UNIs
-mounted chopped exhaust
-set all valve clearances back within spec
-installed all new radiator lines and fresh coolant
-oil change
-shaved the subframe of all unnecessary mounting tabs

So now all thats left is finishing the tank, rebuilding the brakes, and putting in my new jets (just showed up). I had it running on the current carb setup but it was pretty poor as one might imagine. I just wanted to hear what she sounded like after the chop job and wanted to make sure i didnt mess up the carbs or valves too bad with all the adjustments made. Sounds pretty friggin cool with the open pipes but it's gunna piss me off eventually I'm sure so I'm ordering some pipe baffles and steel wool to dick around with. Moving along nicely, should be a fun little toy by the time the roads clear!
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post #7 of 8 (permalink) Old 02-06-2015, 01:26 PM Thread Starter
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first start

here's a quick clip of it's first run after having sat for 5-10 years. This is after the exhaust chop, intake modification, carb cleaning, and valve clearance setting.

https://www.youtube.com/watch?v=VqgGhZ1YkeY

Sounds pretty cool but it'll be too much at highway speeds so a couple 8" baffles are on the way for the pipes
Jeff in Kentucky likes this.
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post #8 of 8 (permalink) Old 02-08-2015, 12:04 PM Thread Starter
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Quick question for ya fellas. In the attached pictures you'll see two unknown inlets on the carbs, both facing the filter side. When I got the bike, i dont recall ever pulling any lines off of these inlets and all i can find in the clymer manual is also attached, suggesting that they are to be attached together and then hooked up to....something? Any idea what these were originally hooked up to? I cant put my thumb on what they might be for, seeing that the bike was up and running moderately well with nothing hooked up to those at all. Any and all advice/knowhow/experience on the subject is welcome, thanks
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