2012 ZX10R ABS Rebuild - More pics - Totally Completed !!

[Maccarocks]

Hi all...

Well I have been busy over the past week as I received my new project, rebuilding my 2012 ZX10R..

I have totally stripped the bike down (didn't take pics of that as I just wanted to keep moving on) but it was down to the bare frame and engine... I have so far fully rebuilt the front.. I had a lot of spare fairings so it is a little bit of a mix and match, but will look pretty much the same as the 2012 black / green model (which it is anyway) but this one is slightly different.. so it's a bit 'custom'

So here is is to date... just waiting on a heap of parts coming from the UK, USA and China (of course) and I need to get a bit of special work done before I fit the subframe, but it will turn out perfect as all my other bikes...

Only 3000k's 2012 ABS model... it's going to look awesome.. More pics to follow..!!

Macca...

[Wattie]

Judging the the back tyre, the 3000km was 3 trips up the Hume.

[Maccarocks]

I would say you are definitely right Wattie..

No lean angle going on with this bike... yet !!!

Macca

[EDU]

If that is even what I'm seeing, how hard is it to fix the subframe mount? Being an amateur at best it is definitely something I would have stayed away from... but it's always good to hear from those with the knowledge!

[Maccarocks]

Well you are seeing correct EDU,

But having the use of some very experienced engineers, I have repaired some very badly bent bikes and they actually become stronger in the affected area than the original. I can get frames straightened exactly to spec.. and you may think it is not possible, but some stock frames are not even exactly straight..

In this case, (and I always do my research before I dive in) I have the broken piece of the subframe mount, and there is clearly a weakness in the design, however this section will be re-welded professionally and also re painted to the OEM frame colour.. and it will be stronger than the other side.. and you will not be able to even tell it was repaired.. It is a very chunky section with one small area of weakness which will be totally fixed.. stand by for the rebuild pics...

I always do my re builds correctly, (I am very anal when it comes to this) and if you have seen any of my bikes you will know how good they finish up.. and I always test ride and set them up at the track as well... so I am happy to risk my life on them to prove that my work is always 100%

Watch this space to see the rear end come alive...

Macca

[EDU]

Thanks for the reply mate! Good to hear from those that actually know what they're doing! Makes me wonder how straight my bike is now...

[Maccarocks]

OK... been a busy boy over the past week..!!

Even got to fit in the Preston Race School at Broadford on Sunday, but have come along nicely on the new rebuild..

So far I have completely re fitted the front end, fairings included, done all the regular mods as far as freeing the bike from it's restrictions, air flapper valve gone, secondary air injection disconnected, K&N, 02 Optimiser, GB racing Protectors, rearsets, Cox Radiator Guard, Woodcraft frame Sliders, M4 exhaust, new subframe, waiting on shorty levers, tank, rear ducktail, evotech muffler hanger, repairing undertray, got to make a throttle insert, need a few small panels re sprayed and some wiring cleaned up and it should be completed by the end of April I am hoping...!!

Here are some pics to date, including the subframe lug replacement.. very professional work as always...

Macca

[Maccarocks]

Got a bit more done,

Fitting the undertray, just cleaning up a bit of the wiring, all the rear tail section and pillion seat, now just waiting on a couple of smaller fairing panels to wrap up this part Sorry about the grainy picture, the light was dropping fast... but you will get the idea.

Macca

[MadKaw]

Looking good, as usual..

Was this bike on ebay or somewhere a few weeks ago, I saw one for sale with busted sub frame mount..

[Maccarocks]

Yes MadKaw.. this was the one..

I did see it before it was listed on ebay (as my mate at Adrenalin generally buys my bikes from the auctions for me) but i just wanted to do a little more research on a few things before I made the purchase... and yes I chose correctly as this one is very straight and going back together really nicely...

I was originally looking for a wet bike and these models are getting hard to get at the right price now. I was even looking at the one in NT, and bidded on that but the insurance company did not let it go through, (price too low) so it was re listed and went for mega bucks this month..!!

So I am very happy with the 2012 model anyway... More pics and updates will be coming..

Macca

[EDU]

The subframe looks great mate... there's no way to tell it was ever broken! Did you do it yourself???

[Maccarocks]

You are right EDU, you cannot tell, and it will be stronger than the original.. lots of penatration there with the weld..!!

People stress out a lot about fixing things on bikes, but if you look at it through the right eyes, most things can be fixed and will be strong and straight and most importantly of all safe...

I dont do this work, you really need a professional engineer who has all the right gear to be able to do this.. but I do know the right people and that is the way to get things done correctly.. That way I know that every bike that leaves my garage is professionally fixed and solid..

Standby for more pics.. I am almost there

Macca

[Maccarocks]

Still moving along well with the re build...

Got all the electrics done and re loomed, undertray is in and all the rear ducktail fairings, so it's almost there..

Will have the tank fitted over the weekend and hopefully the new shorty levers.. almost ready for a test run

I will take better pics when I get it out of the shed...

Macca

[Maccarocks]

Hi all, just another update...

Well after 2 very busy ride days at Phillip Island (25th and 26th April) I returned home with the new tank in hand, Fitted the pump, cap and all the bits to mount it up, even the carbon tank pad to keep it nice, re checked the wiring loom, fitted the tank and started it up.. first kick and sounds really nice... Everything fitted on perfectly with no surprises. The electronics is working as well as both ABS sensors with no fault codes coming up on the dash, so my re wiring is all good. I am still waiting on the shorty levers, got to get the exhaust bung adaptor made and fitted, swap the front tyre over and then it will be ready for a test ride.

Here are a couple more pics looking pretty much completed..

Macca

[tim]

Another top looking build Macca, plans for this one?

Hi all, just another update...

Well after 2 very busy ride days at Phillip Island (25th and 26th April) I returned home with the new tank in hand, Fitted the pump, cap and all the bits to mount it up, even the carbon tank pad to keep it nice, re checked the wiring loom, fitted the tank and started it up.. first kick and sounds really nice... Everything fitted on perfectly with no surprises. The electronics is working as well as both ABS sensors with no fault codes coming up on the dash, so my re wiring is all good. I am still waiting on the shorty levers, got to get the exhaust bung adaptor made and fitted, swap the front tyre over and then it will be ready for a test ride.

Here are a couple more pics looking pretty much completed..

Macca