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Discussion Starter #1 (Edited)
My sister in-law and here Fiance gave me a 96' ZX7R "I was shocked!" (not even my blood related family are that generous) so not being used to that kind of kindness I didn't know what to say except thank you!!! I'm speechless.
A little back story this ZX7R had been sitting outside in the Las Vegas desert sun for 2 years it hadn't run that entire time so the carbs were basically locked up due to varnish and it was also covered top to bottom in a healthy layer of sand & dirt, it had also been laid down prior to its two year parking which had caused a little damage (tail plastic multiple cracks, both sides of lower fairing plastic multiple cracks and pieces missing, upper fairing some small cracks with a small piece missing, front fender lower portion missing, bent left handle bar, also left bar controls cracked and frozen and the windscreen had numerous scratches)
Now trying to keep the cost down but still want it to be nice I have tried to repair what I could and replace what I need to using ebay and if unable to find there then babbits.
Anyway I thought I would post pics of my progress from the start, up to the current state of the project.
Rob

http://s54.photobucket.com/user/wlsnfmly6/media/ZX7R%20Ninja/A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg.html" target="_blank">http://i54.photobucket.com/albums/g110/wlsnfmly6/ZX7R%20Ninja/A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg" border="0" alt="A1 - My 1996 Ninja ZX7R - NAKED - Mar 21, 2013 photo A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg"/>" media="(max-width: 640px)"> http://s54.photobucket.com/user/wlsnfmly6/media/ZX7R%20Ninja/A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg.html" target="_blank">http://i54.photobucket.com/albums/g110/wlsnfmly6/ZX7R%20Ninja/A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg" border="0" alt="A1 - My 1996 Ninja ZX7R - NAKED - Mar 21, 2013 photo A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg"/>" media="(max-width: 960px)"> http://s54.photobucket.com/user/wlsnfmly6/media/ZX7R%20Ninja/A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg.html" target="_blank">http://i54.photobucket.com/albums/g110/wlsnfmly6/ZX7R%20Ninja/A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg" border="0" alt="A1 - My 1996 Ninja ZX7R - NAKED - Mar 21, 2013 photo A1-My1996NinjaZX7R-NAKED-Mar212013_zpsdc7ad044.jpg"/>" media="(max-width: 1920px)">

http://pic2.pbsrc.com/flash/rss_slideshow.swf" flashvars="rssFeed=http%3A%2F%2Ffeed54.photobucket.com%2Falbums%2Fg110%2Fwlsnfmly6%2FZX7R%2520Ninja%2Ffeed.rss" type="application/x-shockwave-flash" wmode="transparent" />Photo and image hosting, free photo galleries, photo editing style="border:none;" />http://s54.photobucket.com/user/wlsnfmly6/library/ZX7R%20Ninja" target="_blank">Photo and image hosting, free photo galleries, photo editing style="border:none;" alt="wlsnfmly6's ZX7R Ninja album on Photobucket" />
" media="(max-width: 640px)"> http://pic2.pbsrc.com/flash/rss_slideshow.swf" flashvars="rssFeed=http%3A%2F%2Ffeed54.photobucket.com%2Falbums%2Fg110%2Fwlsnfmly6%2FZX7R%2520Ninja%2Ffeed.rss" type="application/x-shockwave-flash" wmode="transparent" />Photo and image hosting, free photo galleries, photo editing style="border:none;" />http://s54.photobucket.com/user/wlsnfmly6/library/ZX7R%20Ninja" target="_blank">Photo and image hosting, free photo galleries, photo editing style="border:none;" alt="wlsnfmly6's ZX7R Ninja album on Photobucket" />
" media="(max-width: 960px)"> http://pic2.pbsrc.com/flash/rss_slideshow.swf" flashvars="rssFeed=http%3A%2F%2Ffeed54.photobucket.com%2Falbums%2Fg110%2Fwlsnfmly6%2FZX7R%2520Ninja%2Ffeed.rss" type="application/x-shockwave-flash" wmode="transparent" />Photo and image hosting, free photo galleries, photo editing style="border:none;" />http://s54.photobucket.com/user/wlsnfmly6/library/ZX7R%20Ninja" target="_blank">Photo and image hosting, free photo galleries, photo editing style="border:none;" alt="wlsnfmly6's ZX7R Ninja album on Photobucket" />
" media="(max-width: 1920px)">
 

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Discussion Starter #2 (Edited)
Here are the continuing pics

My 1996 Ninja ZX7R - NAKED - Mar 21, 2013


My 1996 Ninja ZX7R - NAKED - Mar 21, 2013



Carbs off and bypassed the Kawasaki clean air system.


Rebuilding the carbs


Installed a stage 1 Dynojet carb kit


This is what $56 in o-rings & Bowl gaskets look like


carbs after rebuild


Carbs back on


Sync tool came in the mail today, i will be dialing in all the carbs tomorrow


Rebuilding the fuel petcock


Petcock rebuilt


Forks off


Forks off for new seals


Why spend $30 on a specialty tool when you can build one for $12 - (Not pretty but its my homemade Fork cartridge holding tool, Works like a Champ!)


Forks dis-assembled


Homemade Fork oil level gauge, I refuse to pay $23 for a tool I will only occasionally use, when I can build my own, total cost $4.12


Forks rebuilt, new oil seals and back on bike


No more oil leaks


Cooling system flush and refill with new antifreeze, plus oil change to full synthetic and new filter


new plugs
 

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Discussion Starter #3 (Edited)
Left handlebar replaced


New shorty style levers


New Spider grips


Frontend almost Complete


My bar ends finally arrived =)


Modified the D&D pipe into a stubby style


A whole lot shorter and a nice reduction in weight


Looks a whole lot cleaner without the grab rails in my opinion


Nice and tight


before and after pipe mod.


Rebuilding broken body work (view 1)


Rebuilding broken body work (view 2)


Finished laying the glass


Finished laying the glass (alt view)


thin layer of Body filler


body filler sanded


Making something out of nothing at all


Making something out of nothing at all (alt view)


after first layer of glass set up
 

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Discussion Starter #4
after first layer of glass set up (alt view)


After final layers of glass (view 1)


After final layers of glass (view 2)


After final layers of glass (view 3)


body filler sanded


Side plastic repair


Coming together slowly but surely, also glassed over the front turn signal mounts


Laying down the primer


The Tank


Majority of Body work done & Primed


Bodywork test fit


Bodywork test fit


Bodywork test fit


Bodywork test fit


Bodywork test fit


I'll be adding more pics as it progresses further.
 

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Discussion Starter #7
@Green Thx but I have so much more I want to do :)

@Super it wants a password and mine isnt working
 

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Looks awesome but you could have a slipping clutch if you use 10W-30 car oil in your bike. If you want to use less-expensive-than-automotive-oil, I suggest you use Shell Rotella T6 synthetic oil.
 

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Looks awesome but you could have a slipping clutch if you use 10W-30 car oil in your bike. If you want to use less-expensive-than-automotive-oil, I suggest you use Shell Rotella T6 synthetic oil.
+1 on the Shell Rotella T6.

The bike is looking awesome!
 

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Discussion Starter #10 (Edited)
Looks awesome but you could have a slipping clutch if you use 10W-30 car oil in your bike. If you want to use less-expensive-than-automotive-oil, I suggest you use Shell Rotella T6 synthetic oil.
Thx Guys and thx
for the input DJ much appreciated, I will definitely be doing another oil change
 

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Discussion Starter #11
After syncing the carbs I noticed a small oil leak under the bike, my first thought was the drive output shaft seal, but upon further inspection it appears that the Transmission cover may have a crack from when it was laid down, it is all gouged up as if the chain had broke and bound up around the front sprocket, "I have found numerous mickey mouse half ass short cut repairs and mods done to this bike by the previous owner amateur at best that I have had to correct" so this doesn't surprise me" a new cover from Babbits was $101.89 plus $22.20 for shipping which usually takes 9 to 12 days to arrive, but I found a good used one on Ebay for $55 with free shipping and its only about 130 miles from my house so should be delivered fairly quick.
And since I will have to be draining the oil to replace the cover I picked up another filter and a gallon of Shell Rotella T6 synthetic oil. I also have all new seals for the transmission cover so that should insure that its leak free.
Money is a little tight at the moment so the bike has been put on a little bit slower pace in the repairs/mods/resto but next up hopefully soon will be a 15/45 x-ring 520 chain & sprockets conversion.
 

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Discussion Starter #12 (Edited)
New "Used" Transmission cover.


The transmission cover arrived today from Ebay (Total cost $55.)
all cleaned and I just finished installing all new seals, once I get the gasket, on the bike it goes.
 

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Discussion Starter #13
More updates

Vinyl carbon wrap for intake covers



New seat covers, with a textured vinyl


Close up of seat vinyl


Layed down some black paint (pic 1)


Layed down some black paint (pic 2)


More to follow soon :)
 

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Discussion Starter #14
The results after wet sanding and polishing, I only have to lay down the clear coat and wet sand and polish again then it will be ready to go back on the bike.



 

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Oooohh, shiny! I like shiny! Yea, I can be a bling-queen! So, sue me.

Did you de-anodize and polish the upper fork tubes yourself? If so, how did you go about it?
 

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Discussion Starter #18
Here is the end results she's no show bike there are some imperfections but that's okay, Ive always been more about the performance more then the looks, as long as she runs like a raped ape the rest is just icing.I will still continue to add more goodies down the road, New plastic, steel braided brake lines, hopefully a swingarm, forks, wheels and brakes from an 05' ZX10R and quite possibly a ZX9R motor...... but for now she is running once again and quicker then before.
Rob







 
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