TheBrown57 Posted September 28, 2015 Report Share Posted September 28, 2015 Thanks to a good friend of mine I am working my way back on to two wheels! He moved to Cleveland recently and decided to give me his old bike. He hadn't ridden it in over a year and said he knew I would give it the love it deserved. On to the pics!!! It's a 1996 Kawasaki ZX6E (ZZR600 if I am correct)It's definitely not the prettiest bike right now but I'll get that fixed once shes back up and running again. Here she is the day I picked her up from his house. I am storing and doing the work at a friends house near by since I live in an apartment. He also included the "Box O' Parts" he had for the bike when he first got it. First on the list to strip just about everything down and flush the fluids. All the electrical works but I didn't want to attempt to turn it over since it's been sitting for so long. That's all I have for now but i will be updating this as I build her back up. Quote Link to comment Share on other sites More sharing options...
Josh1234 Posted September 28, 2015 Report Share Posted September 28, 2015 Sounds like a great project... Take lots of pics along the way and don't give up! Quote Link to comment Share on other sites More sharing options...
max power Posted September 28, 2015 Report Share Posted September 28, 2015 Subscribe. Good luck and post pics of the progress. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted September 29, 2015 Author Report Share Posted September 29, 2015 (edited) Messed with it a little yesterday. Was mainly tearing it down to check on a couple things. Found out I have a decent amount of plastics still for it so I don't think I will be going the full Street Fighter look but it will be partially naked. On to some pics! Going to find some tail plastics since the ones I have are broken and going to clean up the upper fairing and cowl. Going to sand down the portion where the lower fairing would connect to so it doesn't look like it is missing that piece. Also planning on doing straight pipes for a bit then eventually getting 2 Two Brothers mufflers. Going to need to fiberglass this piece back together That's one way to hold a turn signal in place I wanted to see how the air box looked. And it really didn't look all that bad!This was how far I got before I was running out of daylight and had to pack it up Battery was shot so I removed it and the tray looks pretty clean aside from some random crap Edited September 29, 2015 by TheBrown57 Quote Link to comment Share on other sites More sharing options...
o-no-moto Posted September 29, 2015 Report Share Posted September 29, 2015 Congrats on the project bike. When i was shopping for plastics fkr my fzr i ran into the problem with i could find them but people wanted a arm and leg for anything having to do with fairing parts. I got pretty creative with spare broken pieces and abs cement. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted September 29, 2015 Author Report Share Posted September 29, 2015 All I need is the rear tail fairings and they are pretty cheap online. ZZR fairings are cheaper than ZX-6 ones for some reason. Quote Link to comment Share on other sites More sharing options...
Helmutt Posted October 1, 2015 Report Share Posted October 1, 2015 Nice score on the freebie fixer upper, man. Welcome back Quote Link to comment Share on other sites More sharing options...
Helmutt Posted October 1, 2015 Report Share Posted October 1, 2015 Oh, and get the right side of that subframe fixed up. Looks like it took quite a dinger to the lower leg just behind where it bolts to the mainframe Quote Link to comment Share on other sites More sharing options...
snot Posted October 1, 2015 Report Share Posted October 1, 2015 congrats, on the bike. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted October 1, 2015 Author Report Share Posted October 1, 2015 Thanks guys! It's great to be messing with a bike again that's mine. Oh, and get the right side of that subframe fixed up. Looks like it took quite a dinger to the lower leg just behind where it bolts to the mainframe I'll take a closer picture of it next time I'm working on it but I don't think it's as bad as it looks in the picture above. Someone had spray painted parts of the frame black so where it's been scratched up it looks way worse than it actually is. Quote Link to comment Share on other sites More sharing options...
Gixxus Christ! Posted October 1, 2015 Report Share Posted October 1, 2015 If it's only been sitting a year or two I wouldn't hesitate to try and start it after some fresh gas, it's not going to hurt it.If you run straight pipes, you're gonna have a bad time. Open exhaust, especially on a motor tuned to run dual stock mufflers, will make this bike run for shit. Keep or gut the cans You have until you can buy what you want. 1 Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted October 1, 2015 Author Report Share Posted October 1, 2015 If it's only been sitting a year or two I wouldn't hesitate to try and start it after some fresh gas, it's not going to hurt it.If you run straight pipes, you're gonna have a bad time. Open exhaust, especially on a motor tuned to run dual stock mufflers, will make this bike run for shit. Keep or gut the cans You have until you can buy what you want. I plan on messing with it more this weekend so I'll pick up a battery and give it a shot. I'll take your advice and just gut the stock cans for now. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 4, 2016 Author Report Share Posted April 4, 2016 Bike is officially in my garage and repairs will be started today after work. Parts are already on order as well. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 4, 2016 Author Report Share Posted April 4, 2016 Well I threw the new battery in and she cranks over just fine. Now just need to get her to start. Noticed the bowls on each carb were leaking after attempting to start a few times and that if I put it in 1st and hold the clutch it doesn't want to let me roll it. Quote Link to comment Share on other sites More sharing options...
Gixxus Christ! Posted April 5, 2016 Report Share Posted April 5, 2016 Go over the clutch, make sure it's adjusted properly. If not, you may have an explody transmission or I've seen clutch plates corrode onto each other and lock up before. I've also seen motors sieze at high speed and the momentum shred transmission and clutch. Check cable and adjust, or if it's hydro, replace fluid and bleed. If still no joy, drain oil and remove clutch cover, see if anything grenaded in there. Shake motor, listen for jingles. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 5, 2016 Author Report Share Posted April 5, 2016 I feel like it may be from sitting for so long. Noticed as I tightened up the cable it dis start to work the way it's supposed to but still not fully. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 6, 2016 Author Report Share Posted April 6, 2016 Well it tried to start with some starting fluid so I decided to check the spark plugs. Looks like I need a thin wall socket to get them out. Took off the ignition coils to check them with the new plugs I have waiting to go in. Found that coil for cylinder 2 and 3 is iffy about wanting to spark so I'm going to order some new ones. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 6, 2016 Author Report Share Posted April 6, 2016 Actually before I go ordering new ones in going to borrow a multimeter from work and check everything going to the coils. See if it might be a cheaper fix than replacing everything. Quote Link to comment Share on other sites More sharing options...
Bubba Posted April 6, 2016 Report Share Posted April 6, 2016 (edited) On 4/4/2016 at 7:37 PM, TheBrown57 said: ...after attempting to start a few times and that if I put it in 1st and hold the clutch it doesn't want to let me roll it. Not an uncommon problem in wet clutch assemblies that have sat for a long time. Had the same issue with an old Z1A that was thrown down the road and had been sitting in the back of a friend's garage for a decade or more. The clutch plates basically freeze together--old thick oil, rust, oxidation--and the release springs don't have enough pressure to force them apart. Once I got the motor running, I actually had to get the bike rolling and drop it into 1st and then take it up the street banging shifts thru 2-3-4-5 under power while holding the clutch lever in. It eventually came free and worked flawlessly from then on. If that doesn't work, you'll have to pull the plates and either soak 'em to loosen them or replace with new. Also, if you're not familiar with the tranny in Kaws, they all have a 1st-2nd lockout--a simple spring-loaded ball detent--that prevents the shift forks from selecting 2nd gear from neutral unless the bike is moving. Edited April 6, 2016 by Bubba 1 Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 6, 2016 Author Report Share Posted April 6, 2016 Thanks for the heads up on that Bubba. This is my 4th Kawasaki by my first project bike. I'm enjoying actually running into these things so I can learn something. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 7, 2016 Author Report Share Posted April 7, 2016 First package of new stuff for the bike! Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 7, 2016 Author Report Share Posted April 7, 2016 Carbs are off and soaking in carb cleaner. Hope to give it a shot tomorrow and see how she does. Quote Link to comment Share on other sites More sharing options...
Gixxus Christ! Posted April 7, 2016 Report Share Posted April 7, 2016 I hope you removed all rubber and plastic pieces before putting them in the dip or you're gonna have some splainin to do. 1 Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 8, 2016 Author Report Share Posted April 8, 2016 12 hours ago, CrazySkullCrusher said: I hope you removed all rubber and plastic pieces before putting them in the dip or you're gonna have some splainin to do. Of course! It was actually super easy to get the carbs off which was a nice surprise. Quote Link to comment Share on other sites More sharing options...
TheBrown57 Posted April 9, 2016 Author Report Share Posted April 9, 2016 Couple things got done today. Put the carbs back together and I had it fire a couple times then the battery died so going to mess with it again tomorrow. Quote Link to comment Share on other sites More sharing options...
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