L model build thread, finally - ZX Forums
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post #1 of 90 (permalink) Old 09-29-2016, 01:33 PM Thread Starter
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L model build thread, finally

after such a long time im finally ready to start my L model build.
i bought the bike about 4 years ago, soon after i got it the reg/rec packed up n the plug leads were shot. it ended up sitting outside under a cover for two years then in a garage for the other two years. life got in the way

i got the bike up and running at the start of this year but the fork stanchions had rusted and the brakes were seized. there was also a sticker on the frame where the right hand spar meets the cast section. curiosity got the better of me and i peeled it off. it was hiding a golf ball sized hole thats been filled with body filler.

the bike has a good engine and mint plastics, guess thats all im going to end up using really

so i decided to bring the bike a bit more up to date and have been collecting parts for a while now. heres the list of what ive got for it

new frame, probably going to be painted satin black
2015 zx10r big piston forks
zx9r rear shock, rebuilt and reworked by a previous owner. will be upgraded at a later date.
aprilia rsv wheels
ducati 748/916 brembo front discs
rsv swingarm
brembo rear caliper and master
2005 zx10r calipers tokico
2010 zx10r master cylinder nissin
zx10r clipons and switch gear
SPA design tacho and speedo
carbon front mudguard
braided hoses all round including clutch
aftermarket leavers of unknown origin, probably chinease
steering damper g-force i think
stainless headers of unknown origin, they have a balance pipe across them.


there probably a few other bits. the bike will have a carbon dash with the tacho, digi temp and gear display built in. will be trying to get the weight down as far as possible whilst keeping it UK road legalish (it needs a mot at least)





sorry for the shit pics of the bike, there the only ones i can find of it

Last edited by Pyke13; 11-06-2016 at 04:12 PM.
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post #2 of 90 (permalink) Old 09-30-2016, 12:34 PM Thread Starter
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didnt get as much done as i wanted today, clipons and switchgear fitted. front wheel fits but need spacers made up, 4mm for each end of the axle. the brake discs need spaced out 4mm each to line up with the calipers and the calipers need 5mm spacers due to going from 310 to 320mm discs.
hopefully tomorrow i will able to unpack the frame and see what all ive got with it, i know its got clocks, subframe and wiring loom.
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post #3 of 90 (permalink) Old 09-30-2016, 02:50 PM
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Photos are always nice if you can. Hope to see some.
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post #4 of 90 (permalink) Old 10-16-2016, 10:19 AM Thread Starter
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finally managed to get the frame unpacked, not only did i get the frame i also got the clocks, coils, fuel pump, wiring loom, clutch lever with braided hose, sub frames and swing arm pivot.
i stripped the frame down to a bare frame as its going to be polished, turned out all 4 engine mounts were bust and had to be cut before i could get them out. luckily the threads in the frame are ok. will see about getting new aluminium ones made.

got all the front end spacers ordered and should be here in the next week. dropped the rear pivot axles of to be machined and should get them back during the week. so buy this time next week i should have a rolling frame.





the pics are from the seller before i bought it, i didnt need the mudguard or the swingarm.

Last edited by Pyke13; 11-06-2016 at 04:11 PM.
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post #5 of 90 (permalink) Old 10-16-2016, 03:57 PM Thread Starter
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http://s50.photobucket.com/user/pyke...tml?sort=3&o=0

now ive worked out how to post pics i will get some more up as i get things done. just heard the machinist has broken his ankle and wont be able to machine my pivot axles
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post #6 of 90 (permalink) Old 11-06-2016, 11:35 AM Thread Starter
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so i got the pivot spacers made up. swingarm lines up perfectly to the frame. swapped the bearings on the steering stem and the front end was fitted. eyeing thru from the back the wheels look like there lining up perfectly
i needed two 4mm spacers for the front wheel, two 3mm disc spacers for the discs to line up to the calipers and 10mm spacers for the calipers to raise them for the 320 discs.

theres a few more pics added to photobucket
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post #7 of 90 (permalink) Old 11-06-2016, 11:37 AM Thread Starter
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post #8 of 90 (permalink) Old 11-06-2016, 11:39 AM Thread Starter
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got slightly further than this yesterday but had to strip it back down to finish polishing the frame. i know its sat at a funny angle but its just the bucket its sitting on
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post #9 of 90 (permalink) Old 11-06-2016, 11:42 AM Thread Starter
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so today i started sanding it for the last time before polishing but it needed cleaned
where else would i clean it?

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post #10 of 90 (permalink) Old 11-06-2016, 11:45 AM Thread Starter
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and this is the almost final product, it still need going over with a polishing mop and proper polish not just an old t-shirt and brasso

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post #11 of 90 (permalink) Old 11-06-2016, 02:23 PM
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Looking good!!!!
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post #12 of 90 (permalink) Old 11-07-2016, 06:23 AM
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Coming along nicely
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post #13 of 90 (permalink) Old 11-07-2016, 05:42 PM
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Great progress!

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post #14 of 90 (permalink) Old 11-08-2016, 03:15 PM Thread Starter
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is 2mm aluminum too thin to make the emission block of plates with?
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post #15 of 90 (permalink) Old 11-08-2016, 04:11 PM
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is 2mm aluminum too thin to make the emission block of plates with?
yes. That will warp over time and give you an exhaust leak.

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post #16 of 90 (permalink) Old 11-08-2016, 05:23 PM Thread Starter
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Looking good!!!!
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Coming along nicely
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Great progress!
cheers folks


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yes. That will warp over time and give you an exhaust leak.
ok guess i will have to find some thicker aluminium. cheers
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post #17 of 90 (permalink) Old 11-09-2016, 02:18 PM
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cheers folks




ok guess i will have to find some thicker aluminium. cheers
I wouldn't go thinner than 4 or 5mm.

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post #18 of 90 (permalink) Old 11-13-2016, 03:19 PM Thread Starter
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so a bit of a forced change of plan, i lost my storage and had to be out by the end of the month. so most of the bike has been built this weekend, heres what i started with yesterday

by the end of yesterday i had the engine swapped over and the rear suspension built. this morning start looked like this




as you can see the garage is small and cramped, also it has no power or lights. with both bike in there theres very little room to work so most of the build was done outside. it rained from about 1pm and really started coming down about 2pm which put an end to the fun.
ive got most of it done kinda, the carbs still need plumbed in and the switchgear needs wired up, i have to move the ignition barrel as i cant see a way to get it to work on the zx10r forks.
theres probably a heap more little things i need to da as well.
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post #19 of 90 (permalink) Old 11-14-2016, 04:16 PM
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I like what you have done so far. Frame and swingarm look great. Did the forks yokes go in without much bother?

Not sure what the 2015 Yokes are like, but if they are like my 2008 ones you are probably struggling with the offset key mount? If you have the same problem, once I got the ignition barrel to fit after a bit faffing around then it would only lock the bars dead straight on the steering lock. Not a problem for me on a race bike, i'm going keyless now anyway. I am sure I read a post on here about somebody putting the 6R top yokes onto the 10R stem? They had a barrel mount in the middle so it would line up for the steering lock with the bars turned.
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post #20 of 90 (permalink) Old 11-14-2016, 04:42 PM Thread Starter
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i cant get the ignition to line up, it sits about 5mm forward from the mounting holes. how did you do it?
i dont mind the bars being locked straight, would rather have that than no steering lock.

the way the bolts line up would make a figure of 8, just slightly overlapping. im stuck n cant see a way to do it.
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