Quick (I Hope!) Charity Project - Kawasaki ZZR600

[mikeycee]

Hi Everyone,

Long time no posting for me - Have been lurking back in the shadows for a while!

Ive posted before on here with my RGV Build a few years back, and also a 125 Build that is still sat in boxes in the garage due to Kids and live in general getting in the way!

Not sure how many are aware of 'The Longest Day Challenge' - But I have signed up to do the run this year on June 20th... Ive always wanted to do this and try and raise some good money for Cancer Research UK but things have never seemed to fall right until this year when I thought F**k it, lets do it.

For those familiar with the challenge - You know the drill!

For anyone who may have some change down the back of the sofa - My Just Giving link is below:

https://fundraise.cancerresearchuk.org/ ... lenge-2024

For those who don't, a very brief overview below:

At sunrise on the longest day of the year – June 20th, 2024 – Myself and a group of motorcyclists will set off from Lands End, UK with the intention of seeing the next sunrise 24 Hours later over John O’Groats, the northernmost point of Scotland.

As if that wasn’t difficult enough, we will be attempting the almost 1000-Mile route not just without using motorways, but on motorbikes which have been bought and made road legal for no more than £600.

You guys know that in the motorcycling world £600 doesn’t get you a lot at all... As you will soon see

In brief:

• A route of just under 1000 Miles, with just 24 Hours to complete it.
• No Motorways.
• 4 Pit Stops on the way with supplies and mechanical back up to keep us moving provided by a dedicated team of volunteers.
• Bike purchased and road legal for no more than £600.

By participating in this challenge, we are raising crucial funds for Cancer Research, an organisation leading the charge against cancer through ground-breaking research and support services. Your donations will directly contribute to their efforts to save lives and improve treatments for cancer patients everywhere. Every mile we ride, every donation we receive, brings us closer to a world where cancer is becomes less of a threat.

This really is a big thing for me... I do about 400 Miles a year and a few Trackdays, So will be a huge challenge!

So - On to the project related stuff!

Here is my newly acquired 1990 Kawasaki ZZR 600:





Purchased for £500 and a day out to mid-wales to collect, has not been run in over 12 Months and is no looker

Ive had some new fuel in it, and managed to get the thing running but so far it wont rev above 4k - So a little bit of investigation work to be done, hopefully nothing too serious by the sounds of it.

Plan for the prep is:

• Full engine service (Sparks, Oil, Coolant, Filters etc)
  Investigate and rectify fuelling issue
  Check over brakes and do whats needed
  Check over drivetrain and do whats needed
  Spray it all in tough black in an attempt to make it look less shit
  Add company sponsor logos
  Ride to lands end, then to JO'G, then back home to Milton Keynes

I enjoyed my last project thread, so looking forward to keeping this updated!

Oh - Did I put my link down?

https://fundraise.cancerresearchuk.org/ ... lenge-2024

Thanks, and enjoy the rest of your Wednesday!

[hawkati]

Bloody marvellous. Seeya at the start and hopefully the end as well!

[mikeycee]

Bloody marvellous. Seeya at the start and hopefully the end as well!

Just seen your post!

Definitely will see you there, have been keeping up with your prep progress

[Le_Fromage_Grande]

Does the £600 include the cost of fuel to get it from Wales?
Good luck with it, I think I've got some brand new brake pads for one of them you can have, and maybe some forks, front calipers and a rear wheel (all very used)

[hawkati]

The fuel costs are scarey enough to comprehend that anyone taking part is stumping up a fair old wedge to do the event...let's say £1k at least? Too easy to say that why don't we just throw money at the charity but the loose logic is that the nature of the event & publicity magnifies the donations massively.

I bailed from trying to get the bloody thing going today due to freezing stable & rain outdoors but settled for painting knacked fairing panels & bunging stickers on the bike...

[mikeycee]

Does the £600 include the cost of fuel to get it from Wales?
Good luck with it, I think I've got some brand new brake pads for one of them you can have, and maybe some forks, front calipers and a rear wheel (all very used)

Oh lovely - I may take you up on that offer! I’ll have a better idea on what’s going to be needed after the weekend so I’ll drop you a PM if that’s ok?

Many thank you’s!

[ZRX61]

Ive had some new fuel in it, and managed to get the thing running but so far it wont rev above 4k - So a little bit of investigation work to be done, hopefully nothing too serious by the sounds of it.

Remove the mouse nest from the airbox and/or the acorns from the exhaust.

[Le_Fromage_Grande]

Does the £600 include the cost of fuel to get it from Wales?
Good luck with it, I think I've got some brand new brake pads for one of them you can have, and maybe some forks, front calipers and a rear wheel (all very used)

Oh lovely - I may take you up on that offer! I’ll have a better idea on what’s going to be needed after the weekend so I’ll drop you a PM if that’s ok?

Many thank you’s!

Let me know the EBC code for the brake pads, I was given them and was told they were ZZR600.

[mikeycee]

Let me know the EBC code for the brake pads, I was given them and was told they were ZZR600.

Have dropped you a message with the details, but it's FA158, FA158HH or EPFA158HH dependent on compound. Thanks!

[Le_Fromage_Grande]

My box was full, I'll try and have a look later, I've got the lurgy currently so it might be tomorrow before I get a chance to look.

[mikeycee]

Evening All!

Hope you have had a nice start to the week

Quick update on my Shitheap of a ZZR and its preparations to maybe scrap its way through an MOT this month....

Good news to begin with a check of the airbox for acorns, a check of the exhaust for mouse nests, fresh fuel, and a lot of carb cleaner into the intakes the engine is now revving through the entire range and is actually very smooth. It takes a lot of faff getting it going from cold as the choke seems to be incredibly sensistive and it will tick over, then rev its ass off and I have to reduce the choke slightly as it warms to stop it shaking itself to bits. Once its off the choke it then needs to sit and tick over for five minutes or so before the throttle can be cracked without it choking itself into a stall.

Not ideal - But it works!

So with the engine running, I figured I cannot really get a good idea of its running state until I can ride the thing so I took the decision to start off with getting the chassis in a happy place so I can get it through an MOT and on the road.

Brakes were first up, Front brakes were ok with one sticky piston over both calipers. Gave both calipers a thorough clean out and applied some rubber grease to the piston and after working it in the sticking piston freed up nicely so I was happy enough to put back together. Pads are glazed, but I will work out what to do with them once I've done some road miles and see how they feel.

Rear Caliper was a bit of a nightmare, both pistons jammed solid.... I managed to get them out of the caliper and remarkably the seals are ok, and I regreased and reassembled and they are moving (Sort of) Freely now. Not ideal, but it will do for the time being. I have some new brake fluid on its way and I will be changing the fluid in the front and rear systems along with the oil and coolant etc so will see how they feel and make a call on them .They feel spongy at present but have good bite from what I can tell so far.

Well.... I say change the fluid but I may have an issue getting into the front reservoir thanks to this lovely gift left for me:



Snapped allen key head jammed firmly in the screw head - Lovely! Ill come back to that one.

So brakes all ok for now, On to the drivetrain.

Sprockets both serviceable, chain ok and tightened correctly - But very dirty and dry as a bone with a few bits of light surface rust on the rollers:



Cleaned the chain thoroughly and gave it four rounds of lubricant to get right into the seals. The clean has bought it up nicely and the lubricant rounds have softened the chain up nicely and I think it will be ok - Will see how it fairs once again when its back on the road.

Gears all selecting ok from mucking about with it whilst on a stand so all seems well.

Electrics all ok, everything working aside from a snapped spade connector on the front brake microswitch which I have replaced, Temp gauge working ok.

I can take the key out with the ignition on - So I need to watch that!

Headlights - Its got an LED Conversion fitted.... But the main bulb only serves as a full beam. On low beam it just has the sidelight on, and the main bulb is off. Then when switched to full beam the main bulb comes on to a retina burning laser beam. This LED Light should (I would have thought) have a low beam setting so something is definitely wrong there. I am going to take the headlight out before it goes for MOT and see if I can just change it back to standard maybe - Need to get a look in there and see what the deal is but its a PITA to get into. Need to get this sorted as it will not get through the MOT otherwise.

Only real headache I've had so far is the jamming throttle.... It doesn't return at all. Both cables seem to be in good condition and move freely Ive checked the routing on the cables against the workshop manual and all is as it should be. Ive tried everything and the thing will sometimes slowly return but 90% of the time it will not return at all. The only solution I have found is removing the return cable - Once that is disconnected it snaps shut with no problem at all and is absolutely fine.

QUESTION - Is it ok to run it without the return cable? I cant seem to think of any scenarios where it could be a major issue or even dangerous, Unless someone can tell me otherwise? I would disconnect it at both ends and keep it onboard as a spare if the pull cable snapped so would be handy as a free backup.

So all in all making good progress for the first week, need to get the headlight sorted then in for MOT soon as I want to get on the road soon, do some shakedowns and start getting some miles under my belt in preparation!

Thanks for reading, Ill leave you with some snaps of the premium ZZR quality for you to marvel at











What a f**king beauty!

[Le_Fromage_Grande]

No return cable on cv carbs can be a bit iffy, if the butterflies don't close it will keep accelerating, you can use a big spring instead.

I've been feeling ropey so I haven't had a proper look for those brake pads, they're in one of many plastic tubs

[mikeycee]

No return cable on cv carbs can be a bit iffy, if the butterflies don't close it will keep accelerating, you can use a big spring instead.

I've been feeling ropey so I haven't had a proper look for those brake pads, they're in one of many plastic tubs

Thanks for the steer, do you mean bigger spring as in a bigger return spring on the Carb?

Don’t stress on the pads, it’s no issue at all I’ve got plenty of time - Concentrate on mending

[ZRX61]

Throttle issue: It's a lot easier to fuck about with the cables & housing if you remove the front brake lever.

Choke issue: My ZX11 does the same thing on start up. Easiest cure is one size up on the pilot jets.

Warming up issue: Also cured by the one size up on the pilots.

Snapped Allen: Magnet & faffery.

Front brakes: Pretty sure the pads are the same as the ZX11, the FA 158 looks familiar.

[Le_Fromage_Grande]

No return cable on cv carbs can be a bit iffy, if the butterflies don't close it will keep accelerating, you can use a big spring instead.

I've been feeling ropey so I haven't had a proper look for those brake pads, they're in one of many plastic tubs

Thanks for the steer, do you mean bigger spring as in a bigger return spring on the Carb?

Don’t stress on the pads, it’s no issue at all I’ve got plenty of time - Concentrate on mending

Yes, bigger return spring, but so long as there is a good return spring you should be good.

[mikeycee]

Evening All,

Hope you have had a nice weekend

Quick update on my 'challenged' little ZZR for you....

Throttle return cable removed and shelved, and the whole jamming issue has gone away thankfully. Snapping shut well and no resistance or hesitation at all. I am going to run it like this for a bit and see how I get on, May get new cables at some point but will see what happens.

I have managed to get hold of a replacement LED bulb for a pittance, changed over with no issues and I now have Low/Full beam back with a really good quality white light - Far better than the original LED in there and no doubt far better than the original halogen bulb too I expect!

MOT Was booked in for Saturday morning, and I was in a good position with everything now ready to go - With the exception of a couple of bits I needed to glue back in place that were, Well... A bit Flappy:



So, morning of the test - Take it off the optimate and stick the intake and seat on. Quite excited as this will be the first time I've got to ride the old biffer - Albeit only 2 miles down the road to the MOT Station

Bike out, warm, gear on, ready to go.... Final checks on everything - And the rear brake has gone completely. Pedal down, hits the exhaust and no pressure whatsoever. Must have been when I was messing about with the jammed pistons. Gear off, and a quick sharp bleed of the rear brake and we were ready to do... Thankfully I had some recently used fluid that I had used over the winter on the RGV that was still good for use as a top up. I have some more fluid on order as I am changing out the lot but that was perfect for what I needed.



Off to the test... Not enough miles to get any sort of opinion on the bike but it Passed I am happy to say Rear brake is to be honest neither use nor ornament.... But it tripped the roller so that's good enough for me!

Back home, Taxed, Insured and the mighty ZZR is ready for the road.... If it wasn't for a family party full of screaming kids and possibly some screaming adults too. Back in the garage and no time for a run out.

Happily today was free of family fun days and as soon as the rain cleared over MK this morning I got the engine oil and filter changed, dragged it out onto the road and took my first very tentative miles out on the shakedown run......

Ill start with a positive, I am absolutely staggered at how well this bike handles bearing in mind this is a 34 Year old bike. Its smooth, well sprung and flicks from side to site easily and fluidly. The rear is on the springy side and I need to take a look but there is too much mud, grime and general crap over the shock and linkage to see anything properly so I will take an evening at some point to look into this properly and get it a bit closer to how it should be - Its not at all bad now, so hopefully no nasty surprises!

Engine (Once choke fettling completed and warm) is running very well. I am going to swap the plugs out just as a precaution at some point before the challange and also do another oil and filter change also but very impressed at how clean its running and how well its pulling with no flat spots whatsoever. Bit tappy, valve clearances have probably never been done and sometimes the revs take a little time to settle but it'll do!

Its the comfiest bike I've even rode, aside from the clutch is really heavy and its straining my wrist - But I will try to sort that by changing the position of the lever which I hope will improve things.

The brakes are shit - I mean really shit. The calipers are clean and pistons free, with recent braided hoses. Although not new the pads are in good condition and the hydraulic system is 100% air free.... But they are so bad. I mean wooden, no feel, with the stopping distance of a freighter. Not sure if anything can be done, My issue is I am comparing to modern bikes so could just be the way they are and I just need to get used to them.

So 70 Miles today, decent shakedown and it runs great, handles well and is really comfortable - I'll take that!

I am going to get some more miles in hopefully tuesday if the weather is kind just to make sure I am happy with everything and then I will get to planning my first proper run out. As part of my prep I am aiming to do 3-4 Straight runs of 500+ Miles to get used to time in the seat and distance sharp. I am going to do a couple in the day and some in the night also.... So Ill be on the route planner later this week!

Hope you all have a good week ahead!

[hawkati]

Bloody well done! I'd highly recommend some ebc hh pads for added biteyness, and funnily enough adjusting the brake lever so it doesn't do full on stopping till its nearer the bars and you can apply a proper handful?
It's all relative - the r1 brakes are just fine...but nowhere near as effective as my ducati brembo brakes. Gotta bear that in mind when granny wobble steps into the road

[mikeycee]

Bloody well done!

Thanks! Really glad nothing major has reared its head and that (Unlike your R1!) it’s been relatively straightforward.
I’ll probably need new pads by the time June comes round so I’ll probably look at the EBCs when the time is right!

[hawkati]

Nicely. Get some miles in - it's not just the bike that has to be roadworthy....wibble!

[mikeycee]

Afternoon All!

Hope you are having a nice week.

First night ride on the ZZR This week, As I will be riding through an entire night and into the morning I wanted to try and get a handle on how good/crap the LED Conversion on this bike is. Originally there was an issue where the headlight was on high beam permanently - But I tracked this issue down to a messed up contact in the switchgear and now I have a main & Dipped beam.



Dipped beam is bright - I mean really bright, piercing white light and gives great visibility - Its really wide, but also very high and I think is dazzling oncoming traffic... The beam pattern/spread is quite bad. Hitting high beam makes very little difference aside from I could see the very tops of the trees lining the country roads I was out on

I have the standard halogen set up and a couple of bulbs so I am going to pull the LED and fit the originals back so I can compare the two and make a call - I will run with them and take a spare if its good enough as I really don't want 24Hours of people flashing at me as I'm blinding them!

Rear brake has now been re-bled again and has a good pedal and is actually doing something now!