Progress report... ZX7R Rebuild...

[JiMpiSh]

I spent the good majority of my day yesterday reassembling parts. Cleaned everything by hand that was going back together, except for my front forks. I'm going to wait for the inevitable fork seals and whatever else will need to be redone to them after sitting outside for 5+ years.

I spent about two hours cutting up a large socket to make that damn swingarm pivot lock nut socket, but it worked like a charm. I was debating make a short tutorial post with some pictures for anyone that doesn't have one yet. Cost me 8 bucks and a dozen dremel cutoff discs.

So far I've got my swingarm with rear tire back on. I repacked the rear bearing and cleaned up all the spacers. Cleaned sprocket and hit the rotor with some brakeclean. Hopefully my rusty brakes will work well enough til I can come across some more cash to put into this project. My chain looks like a rusty turd hiding under some clean oil, but it'll have to do until I can afford a conversion kit.

I cleaned the stearing bearings and repacked them before putting the forks back on. As I said, I'm sure the forks will need some tlc in the future. I had my front calipers off, so I put those back on after a quick look over and replacing more rusty pads. Put my brake lever back on temporarily and reservoir and got the the front brakes bled out somewhat. I figure I'll let everything settle and bleed them again later.

To finish my night I threw the subframe on and started routing some of the wiring harness. I now have a rolling chassis and it's most likely time to roll it up my stairs and out of my basement. I'll have to get that rear brake reservoir on and get that bled out too so I have brakes for going up the stairs.

The next problem is figuring out how to carry the engine up to the garage without killing myself or anyone that might be helping me. Drop engine in. Connect harness stuff. Connect throttle and choke. Route clutch cable and get that filled. Hopefully I don't have any clutch problems, but I have a feeling the post that the slave cylinder actuates is stuck in there. We'll see.

I've got pictures of this whole process if anyone cares. I just don't have anywhere to host them at. Anyone have any tips or tricks to share?

[01zx7r]

photobucket.com Hurry I want to see pics

[mpp12]

Same boat as you mate. I have all the parts. in boxes as waiting for more parts.

I have the engine apart, just finished today the expoy porting, and this weekend lap valving (the worst).

Im building a street fighter.

[JiMpiSh]

Pics are up here for the one person across two whole forums that gives a flying f... I'm not gettin answers anywhere and it's frustrating as all hell...

[mpp12]

you are way ahead of me, Im building a fighter here in RD, Im going to use a digital metter
www.trailtech.com vapor

And going with a cyclops headlight and a motocross handlebar.

[NINJARDR91750]

NOT A HOW LOT OF ACTION IN THE ZX7R SECTION! your bike looks like its coming a long well. have you thought about polishing the frame while you have the engine out?

[JiMpiSh]

no, definately not alot of action around here... i started crossposting over at kawiforums.com during the outage....

as for polishing the frame while the engine's out... it's already back in... didn't you see the awesome headlight i'm rockin for now? One side of my bike looks fairly nice with that factory sticker still there in it's big awesome holographic glory, but the otherside is a hot mess... rockin ducttape on the windshield... it'll never be back at showbike status, and I think i like it like that...

honestly though, I think the biggest reason I didn't polish it was because I didn't want the added hassle of having to polish it every time it got a bit tarnished...

[NINJARDR91750]

buy all new white plastic off ebay, then paint it all kawi green, get a acerbis headlight the ride that beast. OR epoxy your plastic now do some sanding paint the fairings black get an acerbis headlight buy a stuntcage then sport the streetfighter look! you will have a different bike than everyone else!

[JiMpiSh]

if i had six hundy for new plastics i'd probably still be spending it on other stuff first... looks just don't matter to me really anymore... i'm just in it for the ride... my brother happens to work at a body shop though. if he keeps insisting I let him get me some paint then I'll have to get some new tail pieces, or at least the right side. Supposedly the left can be plastic welded, but i'd prolly still buy a used one from someone. In that case I'd still rock the kawi green or as close to it as he could get, but I'd prolly get it candied... And as cheesy as that seat is, we all agreed I should just get em both done with some snakeskin or something... That'd be funny shiz.

[mpp12]

Im going street fighter, cyclops and a vapor metter, I will a lot of stuff.

[JiMpiSh]

i'd love to hear anything about the install on those gauges... when i was looking at all the stuff i needed to rebuild i was having a hard time finding any info about aftermarket gauges... post up some pics...

[mpp12]

www.trailtech.net, you need to order the vapor kit for the SV650 (75-600 ), I ordered that one. I talked to the customer service.
Im wating for it....

the sv uses coils and uses radiators so I think it will be pretty easy. also If I need a extra sensor, they sell it.