Creation of a race bike Part II

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Creation of a race bike Part II

Postby photomike666 » Fri Jan 22, 2016 4:36 pm

Between 2007 & 2010 I had a long running thread of the conversion from road bike to trackbike of my 1999 CBR600.

Well, here we go again - this time from statuary write off ZX10 to track bike. Thankfully not my blue 07, but the green 06 I purchased off Burkey late last year.

The bike has 24,000km on the clock & was immaculate prior to the drop. Now nose fairing has a minor crack on the left mirror mount. Left upper fairing has road rash and a lump missing (inc lug mount) from the front. Hero blob broken off left foot peg, scratch on left mirror, scraped left exhaust heat shield, minor scrape to the tail, a bend on the swing arm pick up spool and a broken clutch lever. The swing arm is the reason for the stat write off, but the bike tracks perfectly straight, even with no hands on the bars.

Riding it around the local track (re station car park), I found that it rides fine except the broken clutch lever is annoying, the tyres are a bit worn in the center making streering slow & the front brake was worse than woeful. After a good bleed there was more pressure at the lever, but stopping was terrible. Even grabbing a hand full of brake I could not lift the rear or lock the front.

And so I formulated my Initial plan to complete the bike in three stages; Each stage aimed at lap time improvement, with largest gain for fewest $$$ first.

1) Track ride-able but in road fairings
- New levers
- ZX14 Calipers
- New tyres (OK a pair of Diabalo super corsers one track day old I have in the shed)
- drop forks further through triple clamp

2) Track bike set-up
- Race fairings
- Rear sets
- Stiffer fork Springs
- TRE
- Gearing change (-1 on front)

3) Race bike with all the bells & whistles
- Full exhaust system (GP style would be nice)
- PCV
- Quick Action Throttle
- Re-valve forks & shock (or full rework/replace)
- maybe lighter wheels
- Race Dash
- what ever goodies I can gradually add on as I can afford them

Before Christmas 2015 I started ordering the stage 1 parts; levers and ZX14 calipers. Calipers from the states, levers from UK. The calipers took a guided tours of the entire 52 states before finally winging their way down under, and turned up early Jan. The Royal Mail accidentally sent the levers to Austria instead of Australia, and they have now been declared lots. Seller refunded my $ as he didn't have replacement in stock. I ordered an alternative pair yesterday and hope to see them soon. It really is hard finding an intermediate set of levers; I can't afford top of the line $400+ and don't want a cheap Chinese $50 set.

As for the calipers; well they pissed brake fluid in transit and the pads are soaked. I set about searching for some race pads on the interweb, and found they were more expensive than the calipers! Settled for HH sintered. Whilst I was there I ordered a set of Racetec fork springs to firm up the front. These are in transit & should be delivered Monday (I was hoping for today).

Today I started prepping the bike ready for the front end rebuild, including removal of fairings so I can support the bike for fork removal. Of course I had a little help from my friends...

race-bike-stripped2.jpg
ZX10 stripped 22/01/16


Having removed the fairings, I have decided the upper left is too far gone for the track. So I have reformulated the plan into two stages - track bike for now & more race upgrades later. I'll sell off what road gear I can and use that to fund as much as is possible for now - hopefully race glass & rear sets.

More updates as they happen, but I expect this to be long term :roll:
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby Kwakked Up » Sun Jan 24, 2016 8:51 am

love the alarm system :kuda:
06 zx10r - road
99 zx7r - trackie
77 z1000 - project
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Re: Creation of a race bike Part II

Postby photomike666 » Mon Jan 25, 2016 4:11 pm

Kwakked Up wrote:love the alarm system :kuda:


Thanks, they are great & awesome guard dogs.
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby photomike666 » Mon Jan 25, 2016 4:18 pm

After being scared shitless by the above puppies, the mail man finally delivered some goodies today. Race compound Zx14 brake pads and Racetech fork springs.I'll get these fitted in the next few days, and then I'just need to sell some bits and find race glass. Getting there...
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby Wattie » Tue Jan 26, 2016 9:03 am

Dont bither with tre. If you're under 5k, you're doing it wrong on the track!

I raced my gumby at stock ride height, jacking the rear up and dropping the front wasnt a fix.
But springs are necessity. I had ohlins shock. Sprung and valved front.
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Re: Creation of a race bike Part II

Postby photomike666 » Tue Jan 26, 2016 12:11 pm

Great to know, thanks. Will maybe just look at a gear indicator / race dash then.
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby photomike666 » Sat Feb 20, 2016 8:01 pm

used race glass sorted, thanks OldmanMike :kuda:

Did a quick fiberglass repair and fill this afternoon, tomorrow will be sand back and see what it looks like. Might try and find some 777 lime green for the upper, and do the lower in black like the OEM paint.

Ordered tank grip & black screen.

Once that's all done it will ready for its first outing :)
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby photomike666 » Sat Mar 05, 2016 9:09 am

Between work commitments it's slowly ticking along.

Lower fiberglass repair done & all painted black. Upper has been filled where the gel coat was smashed.

Today I made the moulds out of plastic ready to re-fiberglass the headlight holes that were put in a long time ago. Once that's cooled I'll get it done. & the upper will be ready for paint.

Image

Image

Image
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07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby Wattie » Sat Mar 05, 2016 12:36 pm

mmm gumby powaaah
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ZX10R "Gumby"
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Re: Creation of a race bike Part II

Postby photomike666 » Wed Mar 23, 2016 11:10 am

Fairings are complete, all other bits ordered. Plan to service it this weekend & it's off to PTR next week for some suspension tweaks.

More updates to follow
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby photomike666 » Thu Apr 07, 2016 10:33 am

K&N filters, check
Iridium plugs, check
Silkolene fully synthetic race oil, check
Fork Nix cartridges, check
Racetec front springs, check
Ohlins shock spring, check
Revalved shock, check
Full suspension tune for my weight, check
Geometry set up, check.

Awaiting fitment...
Quick action throttle with 45mm progressive race cam
Cat eliminator y-pipe (awaiting gasket)
Diabalo super corsers
Various stickers
Bolt on GoPro mount (once I decide where to put it)

In post...
Voodoo rearsets
Competition Werks GP Slip-on (may require shave of fairing lower).

First outing booked 17/4 at Broadford :kuda:
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby photomike666 » Fri Apr 08, 2016 1:21 pm

Slip on & gasket arrived

Under seat exhaust & servo removed

Cat removed & y-pipe fitted

Servo elim electronic gadget fitted.

Just rearsets (awaiting collection at post office) and slip on to fit.
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby photomike666 » Fri Apr 08, 2016 1:21 pm

Quick action throttle also fitted.
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby photomike666 » Sun Apr 10, 2016 12:49 am

Rear sets & lower fairing to go

Image
--------------------------------------------------------------------------------------------------------------
07 ZX10R since new, 06 ZX10R tracky , 87 CR250 restoration, Kona Downhill MTB, V8 Ute - I've got serious thrill issues, dude
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Re: Creation of a race bike Part II

Postby Wattie » Sun Apr 10, 2016 5:01 pm

Looking good

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ZX10R "The Crim"
ZX10R "Gumby"
Proudly Supported by Allfixed Automotive 9634 1455
sam & srt, survived
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