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Discussion Starter #1 (Edited)
'96 Rebuild

Hey guys, been a while. So, after a long time coming, I was finally able to start my rebuild. She’s come a long way since the start but I figured while I wait for more parts (and money) I’d post about it.

Quick history - bought the bike 6 years ago, found out it had a LOT of issues, started to fix a few things here and there, turns out I was really good with zip ties. Bike was in at least one bad front end accident (no steering stop, small crack in frame). She had the scars to prove it. So much so that I’ve never considered taking her to a shop to get looked at because I would have been pretty embarrassed. Anyways, this last couple of weeks I had some free time (yay Thanksgiving) and set about a teardown. I’ve had second gear issues for a while now.

So, I start to break down the bike. Crappy fairings off, took the airbox and carb off (everything was filthy and the throttle springs were covered in filth). Then I freed up all the electricals and took the whole harness out. Had to make some cuts and I’ll connect those back up for the tail/blinkers later. Then came the engine. I had no lift, so I paid $1 at Lowes to take 3 pieces of old wood from a trash can and made an engine holder out of it. It’s actually held up quite nicely. Once I had the engine out, I stripped the frame all the way down and cleaned EVERYTHING. She had 22 years of road grime in all her nooks and crannies. I used Nylon brushes and my favorite degreaser (La’s Awesome Degreaser is really awesome) to do it right. I’ll list off the fixes/upgrades I’ve done so far and leave pictures for those of you who can’t read ?

-Re-wrapped seats

-Cleaned Engine


-Rewrapped wire harness
-New fork oil, caps and seals (pretty sure it had original oil and boy, it was solid)
-New (to me) left fork
-Had the frame crack welded and I grinded it
-Had the steering stop re-welded on
-Polished yoke

-Painted the entire frame satin black


-Painted my rims white


-Cleaned out all my brake calipers
-New brake pads (new rear seal kit coming)


-Stainless steel lines front and rear (used off a working race bike - haters gonna hate)


-All new engine cover Cometic gaskets
-New (to me) drive shaft/gears and clutch shaft forks (I split the case)

-Driven racing engine block-off plates





What’s to come -
-2006 zx6r throttle tube assembly/cables
-Slim kill/start switch
-Steel extension plates for my zzr600 fairing stay (bird cage delete) so handle bars don’t hit
-New tires (I’m thinking Dunlop Q3+ ?)
-Safety wiring
-Race fairings down the road (belly pan w/oil catch) ~ when money allows :nerd
-Airbox/tubing upgrade ~ when money allows
 

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So far, so good Brandon. How about the wheel bearings, steering neck, and swing arm bearings? Hopefully you'll never be this deep in the bike ever again.

Off this topic, did you get the platform you wanted? Did SERE s*ck As much as I think it did? ;)
 

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Discussion Starter #4
So far, so good Brandon. How about the wheel bearings, steering neck, and swing arm bearings? Hopefully you'll never be this deep in the bike ever again.

Off this topic, did you get the platform you wanted? Did SERE s*ck As much as I think it did? <img src="http://zx6r.com/images/smilies/winkwink.gif" border="0" alt="" title="Wink" class="inlineimg" />
Yeah I checked all the bearings and re-greased them - none of them were grinding or looked worn/bad. I just hope the fix worked! As a side note, This is the third time my sprocket nut has been super loose so i need threadlock and really torque her down.

As for good old Ft. Rucker, SERE was definitely not the most fun, but it was a good learning period. I’ve actually been on hold for a while waiting for common core to start (lots of people here). Just crossing my fingers I can select Apache!
 

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Discussion Starter #5
Bled the front brakes tonight (rear rebuild to come) and everything I saw online was telling me to get a vaccum thingy. I didn’t, and it was still a piece of cake. Not sure if the ss lines make it easier, but after getting straight fluid and no air (and no lever pressure), I cracked the banjo bolt at the master cylinder and a ton of air came out. Soon as I did that I got brake pressure. Didnt take much time at all, things are starting to come together.
 

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Discussion Starter #7
Of course yes, new washers, new (correct) fluid, new pads, clean rotors,etc. doing it all right this time.
 

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Discussion Starter #8
Having a hard time figuring out why my triple tree always wants to be turned slightly to the right when the alignment gets done for the forks. The forks are straight, everything seems to line up and the wheel spins nicely, yet the triple tree is consistently off-center. Steering stem bearings seem fine, no wiggle and no binding. Thoughts?
 

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One of the clamps are bent.....

Alignment, only the lower is tight, axle, fender, anything else is loose....... Grab a fistfull of front brake and force the front to compress all the way multiple times?
 

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Discussion Starter #10
One of the clamps are bent.....

Alignment, only the lower is tight, axle, fender, anything else is loose....... Grab a fistfull of front brake and force the front to compress all the way multiple times?
I'll try that first. Would be a shame to have to replace the clamps but if that's what it is I wont hesitate.
 

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Discussion Starter #12 (Edited)
Some updates Fellas.

Had to take the engine out and split the case again - turns out one of the forks had fallen before I had everything tight and it got wedged off of the shaft :coocoo fixed that. Put the engine back in and she shifted like butter.

Next, I upgraded to an 06' throttle assembly, had to add a few silicone washers for the longer length but overall not a bad fit, and much much better than the old start button throttle assembly. Wired in a thin start/kill switch and drilled some holes for them to sit in perfectly. Should probably take a picture of that instead of the cables going over the res.

Completely rebuilt the rear brake - new seals and all. She needed it (broke a seal on disassembly).

After that, I re-upholstered my seats with some walmart fabric. Not a bad job if you use a heat gun and take your time.

Lastly, not pictured is the safety wiring I started. Drilled a hole in my oil drain bolt and wired that and the oil cooler banjos. Also did my oil filter. I'm thinking once I do my tires I'll wire the brakes.

I have a new (to me) lower yoke with good bearings to put on once I buy my tires, front and rear wheel bearings, and new bolts all around. That should straighten my front end out. After that, the only thing left is to buy track fairings well down the road when I have another, newer bike to use on the street.
 

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Discussion Starter #14
<golf clapping>

Brandon, I don't recall if you re-sprung the bike for your weight...... Well worth the money. Imho the second best mod you can make.
Once I fixed the fork caps and did my oil flush job, I sprung the front for my weight. I believe the rear was good to go for my weight already, but I plan on checking again after my tire change.
 

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Discussion Starter #15
Yesterday I did a thing. Never had the correct front fender so I ordered a used one to paint. Found out after a deep clean that it has severe cracks all around each bolt hole, so I used my cheapo soldering iron and did some plastic welding. Think it turned out alright in terms of strength and now she’s looking good.

I sanded the front fender and my new rear hugger (found out it was real carbon fiber, bought on ebay from a guy who didnt need it - it needs some holes drilled still) and painted them satin black. Did some wet sanding before a final coat to really bring out the smoothness. I’ll save the install for my new Q3+’s, wheel bearings and new (to me) lower clamp.
 

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Very cool! Track bike or commuter bike? i have a J2 (2001). They share a ton of parts. I did block off plates, jet kit and timing advancer! Why did you go with the 05 throttle cables and tube? shorter throw?
 

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Discussion Starter #17
Very cool! Track bike or commuter bike? i have a J2 (2001). They share a ton of parts. I did block off plates, jet kit and timing advancer! Why did you go with the 05 throttle cables and tube? shorter throw?
Commutter for the time being, hoping to get on the track once I have the time to do so. I went with the 05 throttle because my old throttle assembly spun on the bar and the 05 was external to the starter assembly. The 05 cable is slightly longer so I had to use rubber washers as spacers but it functions way better than my old assembly did and is much more solid too.
 

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Discussion Starter #18 (Edited)
Update: this weekend I replaced all my wheel bearings front and rear with an All-Balls set, installed the new (to me) lower yoke with new bearings and plenty’o grease, and installed my new (to me) front fender and carbon fiber (painted black) rear hugger.

The tires were the worst mistake of my life in terms of doing it myself... took me all day yesterday just to get them on the rim (ruined my paint job in the process of course but I’ll fix that later), and could not for the life of me get the bead to fully seat. Took it in this morning and five minutes and zero dollars later I had filled tires. The cornering characteristics are totally different now, it feels like a completely different bike and will take a bit to get used to, but I can already tell they are super-glued to the road compared to my Continentals.
 

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Looking damn good from what I can see.

We need some good pics of the bike now !
 

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Discussion Starter #20 (Edited)
I’ll try and take some this week, I have pretty busy schedule. The plastics are completely shot, but the internals and mechanical pieces are almost all up to date now. Some time down the road she’ll be strictly track oriented and I can gut a lot of the crap and get new fairings but for now she’s happy.
 
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