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AjR1's ZX6R Track Bike Build

Discussion in 'Modifications and Projects' at netrider.net.au started by AjR1, Oct 13, 2012.

  1. Hi Guys,

    Well I decided to buy myself a track bike and the perfect choice was an Old 98 Model ZX6R.

    So here is a bit of a run down of my track bike build.



    I have been progressively sorting it out over the last couple of months.

    It was a bit tardy looking but mechanially all good from what I could see.

    I just had to get it home and start stripping it down for a once over.

    I will be replacing the race glass with new model plastics to change the look eventually but for now it will just get a freshen up.

    How it looked in the ad.

    zx6r.

    All loaded up ready to go home.

    trackie.
     
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  2. First things first , I had to strip off all the glass and Tank.

    Some fresh Plugs, Filters, Oil, Coolant, lube up all the pivot points, cables etc.

    Then get it ready for prep and painting of the frame/swinger, and then start preping the glass for paint while I wait for items that needed replacing to arrive.


    Bikes home and ready for the strip down.

    SAM_1474.

    SAM_1477.

    SAM_1478.

    SAM_1479.

    SAM_1481.

    SAM_1482.

    SAM_1483.

    SAM_1484.

    SAM_1485.

    SAM_1486.
     
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  3. High as a kite on paint fumes and the frame is all painted. Now just gotta let it all dry.

    SAM_1519.

    SAM_1520.

    Well after getting around to removing the braking system.

    SAM_1522.

    I found that the rear caliper was seizing up.

    So after pulling it all down.

    SAM_1523.

    There is a bit of corrosion going on.

    SAM_1524.

    Since I will be overhauling the rear I may as well do the fronts aswell, So its time to order some caliper kits and clean these up & paint while im waiting for them to arrive.

    Well I finished off the Pair Valve mod. So only fresh air into the motor from now on.

    SAM_1525.

    Also changed out the plugs as well today.

    SAM_1526.

    Gave the frame & swinger its 6th and final coat.

    Plus all the other little bits aswell.

    SAM_1527.

    SAM_1528.

    And also rotated the bottom shock mount 180deg so the adjuster is not blocked by the exhaust
     
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  4. The exhaust had some rash damge so decided to turn it into a shorty.

    SAM_1529.

    SAM_1530.

    Next step Cermaic coat black

    Bought a few things for the Trackie today

    Tinted DB Screen

    screen.



    Clear SS Lines F&R

    braidedlines.



    Black Fuel Cap

    fuelcap-1.



    Green levers but with orange adjusters

    greenlevers.



    Rearsets

    FR00013_2.



    Rear Cowl Decal

    zx6rstikers.



    Frame Sliders

    CrashKnobs.


    Header Gaskets

    exhaustgaskets.
     
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  5. Fork Adjusters

    forkadjusters.



    Tank Decal - But in Black

    kwikasfukisticker.



    Various Michelin Decals for front fender etc...

    michelinstickers.



    Upper Ninja Decals

    NinjaStickers.



    Black Oil Cap

    oilcap-1.



    Rear Caliper Kit

    rearcaliperkit.



    Rim Stickers to replace the current blue ones.

    rimstickers.



    Various Sponsor stickers for the belly pan etc...

    sponsorstickers.
     
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  6. Slowly Starting to go back together. Kinda looks like a bike.

    26.



    Filling in the holes in the exhaust where the badge was rivited. Will fill it up again one set and then sand it back ready for more paint

    21.



    Base coat on the race glass all done. Now just have to let it cure for the week before taping it up and doing the top colours.

    22.

    23.


    Since the glass is going to be replaced later on it was just a quick job, The tank on the other hand will not be replaced and I'm taking a bit more care with the prep and finish on this one. All sprayed up with primer filler. Couple more coats to go and then ready for a light sand and paint.

    24.

    Rear caliper all cleaned up and painted. Excuse the white paint dust. Will wash right off with the first bath once its all back together.

    25.

    I have got the base coat down on the tank. 7 coats in total and still one more to go. Then its curing time for a week before taping it up for the top coat colour.

    Here's a few pics of my pressure pack handy work. :topstuff:

    SAM_1548.

    SAM_1540.

    SAM_1541.

    SAM_1547.
     
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  7. And a couple of close up shots.

    SAM_1544.

    SAM_1545.

    Well I decided I'm to impatient to wait so taped up the tank and layed the first guide coat of colour.


    SAM_1555.

    SAM_1554.

    SAM_1552.

    SAM_1551.

    SAM_1550.

    SAM_1549.

    SAM_1559.

    SAM_1558.
     
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  8. Well the tanks almost done.

    SAM_1577.



    Close up (Not to shaby for a rattle can)

    SAM_1578.



    Rear cowl where my young fella dragged it along the concrete.

    SAM_1573.



    All taped up ready for the green.

    SAM_1574.

    SAM_1571.



    Did someone say "Sexy Tank"

    SAM_1583.

    SAM_1579.

    SAM_1580.

    SAM_1581.

    SAM_1582.
     
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  9. Well I started to paint up the tail. Had to change the layout of colour slightly due to the damage my young fella did to the white paint. So just covered up the good and painted over the bad areas.

    First up with the green.

    SAM_1585.

    SAM_1584.


    Well 2nd stage of the rear cowl all done. Just have to wait for it to cure and then time to tape it up again and paint the top orange.


    The green actually looks nicer than I thought it would based on the colour of the cap.

    SAM_1590.

    SAM_1587.

    SAM_1589.


    Got the rear cowl finished off and clear coated,

    SAM_1595.

    SAM_1594.

    along with the tank and installed the new filler cap.

    SAM_1596.

    SAM_1597.

    SAM_1599.
     
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  10. Upper &Lower's painted up with the green, just have to tape it off again tomorrow and finish off the orange, touch up the white where my young fella scratched it up and clear coat it all.

    SAM_1602.

    SAM_1601.

    Front fender all painted up and clear coated

    SAM_1604.

    SAM_1607.

    Tomorrow I'll be Installing the levers, rearsets, fork adjusters and work out how I'm going to get the front off the ground to remove the wheel so I can paint up the forks & front wheel. Stick the tank pad on and get the rear end of the bike reasembled atleast.

    Left rearset installed.

    SAM_1619.

    Fork Adjusters Installed

    SAM_1611.

    SAM_1612.

    Oil Cap Installed

    SAM_1614.

    Rear Brake Master Painted Up. Just waiting for it to dry and then I can assemble the Right Rearset

    SAM_1615.

    New Levers

    SAM_1616.
     
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  11. Clutch side installed

    SAM_1617.

    Brake side on the master.

    SAM_1618.

    Well I did a little more tonight and will be back out in the garage shortly once everyone is asleep so I can work undisturbed.

    Removed the blue rim tape and installed the new decals

    SAM_1620.

    Looks the part now.

    SAM_1623.

    Installed the rear wheel again and adjusted the chain (excuse all the dust and mess, My apprentice was off today)

    SAM_1624.

    Brake Caliper Bracket all painted up.

    SAM_1625.

    Rear cowl & Seat mocked up before final install.

    SAM_1628.

    From another angle with the new decal

    SAM_1627.

    Pretty happy with the progress so far.

    Tank is completely finished. Decals & Tank Pad on.

    SAM_1643.
     
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  12. Upper is all painted up, Just need to let it cure then its time for a rub back and clear coat.

    SAM_1631.

    SAM_1632.

    SAM_1633.

    SAM_1635.

    SAM_1636.

    Lower is all finished and belly pan decals applied.

    SAM_1638.

    SAM_1640.
     
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  13. Ok so do we all remember the Before Photo??? :LOL:


    BEFORE :-s8-[

    trackie.
     
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  14. FINAL PRODUCT :biker::beer:

    SAM_1807.

    SAM_1806.

    SAM_1805.

    SAM_1804.

    SAM_1802.

    SAM_1808.
     
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    • Like Like x 1
  15. Great work mate - from reading the thread all in one go it feels like you did this in 2 days!

    Remarkable transformation......big props (y)
     
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  16. Great workmanship and was interesting to see the transformation through the shoots.
    How long did this all take?
     
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  17. Holy shit! That looks amazing, very nice work there! Can't wait to get my own track bike!
     
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