ZZR400K - Build

[wr6133]

Well I liked my ZZR400k (400 version of a 600D) enough that I decided I wanted a nicer one. Now as you can’t get one new anymore (and I couldn’t afford if you could), I decided the only way to get what I want is to build one.

I have a sporadic shoestring budget, no garage to work in and I’m trying to rebuild a 23 year old bike that was never officially sold in the UK and had a short production run. Yes I’m probably stupid.

Now when I began to plan on paper my dream build included

New fairings

All electrics and clocks from a 600D

Entire front end (forks, yokes, etc) from a 1995 onward 600E/400N (they have adjustable preload)

Nissen callipers from a CBR

Hagon shock

New tank

Budget and reality have set in a bit though. The callipers have been dropped I have a spare set of Tokicos I’ll try to recondition. New fairings are impossible (not made) so they will be a case of buying piecemeal on eBay as decent used ones appear. The 600E front end has been dropped as budget probably won’t allow. The Hagon Shock is dropped on budget grounds too, I have a spare standard shock that needs cleaning up and will hopefully buy a better spring to replace on it.

To start with I had a large amount of spares,

Forks – Need work

Engine – Needs a total stripdown and rebuild as unknown condition

Callipers and master cylinders – Both front and rear

Wheels – Need a good cleanup and painting

Rad – Needs a clean but functional have about 5 coolant reservoirs to go with it

Swingarm – Needs a clean

Sprocket carrier – Needs a clean

Various other bits I can’t remember off the top of my head

I bought a frame on eBay for the princely sum of £15. It’s legit, straight and undamaged.

Plan is to have the frame and swingarm powder coated. Cheapest quote I can find is £150. With the sporadic shoestring budget that will take a while to get saved up.

In the meantime I will clean up the bits I have and keep an eye on eBay for bargains I need.

Anyways some photos to start this build log.

The frame

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140820_160428_zps02649aa5.jpg

A dirty engine

http://i1249.photobucket.com/albums/hh504/wr6133/_57_zps91e151ce.jpg

Sprocket carrier before cleaning

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140915_125838_zpse5a7f553.jpg

And afterward

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140915_143320_zps88d074e6.jpg

Found this sprocket in the pile of parts I have (they came with the current ZZR) looked in good nick so cleaned it up too.

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140915_153217_zps4392ebc5.jpg

Have a 4-1 collector and pipes. I actually want a standard 4-2 on the bike as the 4-1 creates flatspots (my current ZZR has a 4-1).

Cleaned it up though incase it does get used

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140915_155725_zps1723fd6b.jpg

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140915_161518_zps9add840b.jpg

You all may want to buy shares in WD40 the amount I’m going through the company may have a bonanza year.

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140915_161330_zpsd4d831d4.jpg

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140915_162512_zps49e06345.jpg

Cleaned some other bits

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140917_122648_zpsa6ae19e4.jpg

A prior owner had stripped this screw it had then rusted in place

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140917_122826_zps245dcb97.jpg

Hacksaw and leatherman sorted it

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140917_123220_zps11c362b9.jpg

Then degreased. Will need sanding down to remove someone’s shit attempt at painting it

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140917_124840_zps63edbec7.jpg

Today I have started to strip the callipers.

Front M/C, will need a total rebuild the rubber seals are dead.

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140918_091256_zps217a1a63.jpg

Calliper, the pistons are completely seized.

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140918_091305_zps96658d11.jpg

I don’t have a greasegun or airline so trying boiling to get the buggers out

Some tabasco with your entrée?

http://i1249.photobucket.com/albums/hh504/wr6133/IMG_20140918_093940_zps1e30ad01.jpg

That’s where I’m at now. This will be a slow build. Not a lot of disposable income so things like powder coating will take a while to save for. Also in no rush as I have a ZZR already on the road.

[wr6133]

An update.

After I started this thread I had an off on a work bike, fractured my elbow and worsened a spine injury, so not a lot got done. Also I’m now out of work and waiting on the NHS to do something more useful than dope me up on Tramadol to sort my spine. Means budget is now non-existent and physically I struggle to get shit done.

However got sick of doing nothing so decided to start on the stuff I do have. That filthy spare engine got cleaned and today popped the lid to check the valves………. They were way, way out. As they were so far out I figured may as well pull the head to check the rest of it.

Sorry for crappy photos, phone isn’t the best and it was also a bit greasy.

My mancave… that’s my work area, it’s a bit tight!

http://i1249.photobucket.com/albums/hh504/wr6133/zzr/IMG_20141109_185036_zpsd6ba315d.jpg

Cleaned these up a bit

http://i1249.photobucket.com/albums/hh504/wr6133/zzr/IMG_20141109_181013_zpsbaccfb5a.jpg

Still not gleaming but better, I was worried they’d be knackered as the clearances were so far out but they appear ok

http://i1249.photobucket.com/albums/hh504/wr6133/zzr/IMG_20141109_184537_zps523ac30d.jpg

Crap photo but in much better condition than I thought

http://i1249.photobucket.com/albums/hh504/wr6133/zzr/IMG_20141109_183740_zps54045e01.jpg

http://i1249.photobucket.com/albums/hh504/wr6133/zzr/IMG_20141109_184635_zps019188f4.jpg

Haven’t really looked at this yet. A quick glance I think the rings will need replacing.

http://i1249.photobucket.com/albums/hh504/wr6133/zzr/IMG_20141109_184429_zps75905f67.jpg

I’ll be doing more in the week.

None of the bloody shims were marked so I need to get a micrometer to measure them. Then need to find some dirt cheap shims.

Gaskets are going to be a royal pain. The head gasket has lost all its black layer so shouldn’t be reused. However the only way to get a ZZR 400 head gasket is from japan at near £100 posted which is out of budget, also if I add the cost of the other gaskets (which luckily are common with the 600) I need it will total around £150 which is close enough to the price of a used 600 engine that would bolt right in.

Piston rings I haven’t measured yet, I’m hoping they are common with the 600 so replacing would be easy and cheap.

Anyway stay tuned for more engine fiddling through the week.

[eastanglianbiker]

think you will find pistons are not same diameter as the 600 so will need to buy rings for the 400 and before buying them check the bore for wear as you might need to upsize the pistons to +20 or more so extra cost again but not worth just doing rings without measuring and checking if its within limits

[wr6133]

think you will find pistons are not same diameter as the 600 so will need to buy rings for the 400 and before buying them check the bore for wear as you might need to upsize the pistons to +20 or more so extra cost again but not worth just doing rings without measuring and checking if its within limits

 

Spot on.... I was checking yesterday and the 400 rings are different. They also seem to only be available from 1 person on eBay who is in Hong Kong and wants 27 quid a set. I need 3 sets so 81 notes on rings. More than I will spend. I'll probably just scavenge the best parts from this engine and the best parts from my current on the road ZZR400 engine. 81 for rings + whatever shims I need the cost would be too close to what I could buy a working 600 lump for. My wife is in China next month though visiting family so I may get her to see f she can find any locally at local (peanut) prices.

This resto now is more about keeping busy than the initial lofty plans I had. Not being in work and being effectively crippled and drugged up all day has been taking its toll this is to get me busy before I go insane. If I can get all my parts sorted over winter then hopefully come spring if I have regained mobility/strength I will tear down my current ZZR400 hack and use parts from that along with the restored stuff in the spare frame I have.

[Mr Fro]

Shims aren't that bad - a couple of quid a pop from wemoto.