ZX6R Restoration

[mealexme]

I posted on this site almost 6 months ago about buying a ZX6R to do up over the winter.

Here she is

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123100_zpsoly2gx5x.jpg

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123053_zpsclacsjui.jpg

So what's wrong with her? Maybe its easier to tell you whats right.

Well, it serves well to reserve my parking space whilst I'm out...

And what's wrong? Well, how long do you have?

Having not ridden it since that one week in October I spent commuting on it to find any issues, the following is from memory:

[strikeout]The key is hard to get into the ignition barrel and gets stuck when trying to remove[/strikeout]

Handle bars/forks are bent

There is a slight shake in the handle bars at about 85/90mph which disappears at 95+ (not good if I want to take it onto track)

[strikeout]Throttle cable sticks[/strikeout]

Seems to lack power down low (which could simply be due to it being a 15 year old bike and may not actually be an issue)

Judders at low revs, like it's struggling more than it should

Rough idle

Front headlight cracked

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123108_zpsodjrrwuf.jpg

Every panel either cracked or scratched

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123126_zpsjpgli1tc.jpg

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123214_zpsgqbzlzeu.jpg

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123244_zpsccqsomm5.jpg

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123126_zpsjpgli1tc.jpg

Paint on the frame and engine casing looks original, but looks as though it's either running or had something spilt in it, leaving streaks in the paint

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123517_zpspg5xsukl.jpg

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123159_zpsbidux1lq.jpg

The whole chain bright orange with encrusted rust

Rear tyre bold

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160308_123353_zpsm2jemafd.jpg

Front brakes both drag and are ineffective at stopping.

And after all of that, would you believe I bought it with a fresh MOT?

Also it's a cat C, with no mention of which in the description

Anyway, now I have some spare time, a bit of spare cash after saving up all my pennies to move out (moved 2 weeks ago), it being lighter longer and actually warming up, I can finally get round to fixing her up.

Edited March 13, 2016 by mealexme

[Hoggs]

Well sounds a project and a half! Look forward to the updates

also you should make it green

[RantMachine]

Well sounds a project and a half! Look forward to the updates

also you should make it green

I was waiting for that

Doesn't sound too bad, I reckon! Well, not too bad when you also have a working bike to ride when you need to work off some frustration

Looking forward to your future posts about it!

[Stu]

Not a great deal to do to be fair!

If it's the original tokico 6 pots then ditch them and replace with nissin 4 pots

Its cheaper and you will have better brakes

[Firebladewickers]

I had the exact same bike in green with green rims.. Very nice bikes when looked after she just needs a lot of tlc good luck dude!

[mealexme]

Not a great deal to do to be fair!

If it's the original tokico 6 pots then ditch them and replace with nissin 4 pots

Its cheaper and you will have better brakes

 

Really? I thought the more pots the better?

[fq-craigus]

Not a great deal to do to be fair!

If it's the original tokico 6 pots then ditch them and replace with nissin 4 pots

Its cheaper and you will have better brakes

 

Really? I thought the more pots the better?

4 good pots vs 6 ok pots the 4 win!

[Stu]

The tokico 6 pots are really shit!

Its not all about the number of pistons its the surface area they have!

The 4 pots have larger pistons

[MR_W]

This should be good

I shall await further updates

and paint it any colour but green

[Hoggs]

and paint it any colour but green

I HEARD THAT!!!

[MR_W]

and paint it any colour but green

I HEARD THAT!!!

 

Heard what?

[mealexme]

One of the first things I noticed when picking up the bike is a problem with the ignition barrel. When trying to insert or remove the key, the key jams. Once its in however, it works smoothly, which to me suggests there is an issue with the key getting stuck in the barrel, or the key getting stuck on the wafers. (for those who don't know about locks, heres how a motorcycle lock works

">

" onclick="window.open(this.href);return false;)

If you try and get a key direct from Kawasaki, they can be stupid money, but luckily you can buy anything online these days. Just over a fiver for a replacement key delivered to my door, thank you Mr Ebay

Unfortunately a new key makes no difference what so ever, so it looks like I'll be taking the ignition barrel apart to have a look at the wafers

Problem is, these tamper proof bolts

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160311_151249_zpsd4llhksq.jpg

Which have to be drilled

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160312_125918_zps4ha4mbav.jpg

Before removing the wafers

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160312_140533_zps2uae7pl2.jpg

Cleaning them all up and putting them all back in

http://i1223.photobucket.com/albums/dd519/mealexme/bike/20160312_143547_zps0orzvkka.jpg

It's as easy as that. Unfortunately it doesn't quite move as smoothly as a brand new lock, but its 16 years old and no longer do I have to use so much force to get the key out that the bike almost comes off the stand.

[mealexme]

The sticky throttle issue has now been fixed.

After taking the grip off, lubing everything up including the cables, the issue still persisted.

Luckily, before buying a new throttle cable, I decided to re-route the cable.

As good as new