1991 Kawasaki Zzr600 Resto Build

Discussion in 'Other Bikes' started by Stuart Maranellohouse, Apr 2, 2023.

  1. Hope I'm allowed to post this and its in the right place. First bike I ever owned was a 91 ZZR600 so when this cheap one came up for sale locally at the start of the year nostalgia got the better of me and I bought it with the plan to restore it but to paint it my own paint colour keeping its original lines and layout.
    Apologies for the writing on the bike, the stickers where the work of the previous owner along with the paint scheme. He painted it like that as he didn't want anyone nicking it!
    How I got it.
    zzr just home.jpg

    zzr just home 1.jpg
    Bike being stripped.
    zzr being stripped.jpeg
    When I got that far I headed off to see my mate who manages a paint shop and we spent 3 hours deciding on the paint. The base paint was decided on.
    zzr primary colours picked.jpeg
    I say base as we then played around with adding pearl and candy mix until we got the colours the way we wanted them.
    zzr paint mixed.jpeg

    With that out of the way we matched the frame and casing paint.
    zzr matching silver for frame.jpeg
     
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  2. Frame primed.
    zzr frame primed.jpeg
    Rear hanger, casings and trim primed.
    zzr parts primed for silver paint.jpeg
    Frame painted.
    zzr frame painted.jpeg
    Parts painted.
    zzr parts painted silver.jpeg

    Oh and all the black bits have been left into another mate to be powder coated.
    IMG_0026.jpeg
     
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  3. Can I ask why you didn't remove the frame from the engine to paint it?
     
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  4. I didn’t want to strip it down any further. Probably should have I suppose.
     
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  5. Got all the black bits back this morning freshly powder coated.
    zzr black bits powdercoated.jpeg
     
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  6. Having to clean and strip everything is slow work, its the little things like removing paint from the bolt end caps without damaging them that takes care and time.
    zzr bolt covers.jpeg

    Painted the wheels so in between coats I started to strip the tank, with a scraper! only ever had to do that to paint once before.
    zzr removing paint on tank.jpeg
     
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  7. So far the rebuild is going without a hitch, weirdly!
    zzr being rebuilt.jpeg
    Even the new stickers that weren't due for another week or so arrived today.

    zzr new stickers.jpeg
     
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  8. After all the paint scraping is now finished I thought it wise to Barcoat the panels to ensure there is no contamination seepage from the old paint.

    zzr barcoat.jpeg
    zzr barcoat 1.jpeg
    zzr barcoat 2.jpeg

    Next a coat of primer.
    zzr first pime.jpeg
    zzr first prime 1.jpeg

    The coat of primer helped me see all the imperfections left from using the scraper. Stoppers will sort those out.
    zzr removing imperfections 1.jpeg
    zzr removing imperfections.jpeg
     
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  9. Update.
    New tyres bought and fitted.

    IMG_0222.jpeg
    and finally got the grey paint on today.

    IMG_0223.jpeg

    IMG_0224.jpeg
    In between the 4 coats I took to the rear lens to see how well I can bring it up. Not sure I can, its badly faded.
    IMG_0221.jpeg
     
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  10. absolutely.....engine out....if youre gonna go that far strip the engine and coat that as well...
     
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  11. interesting colour of oil in that drain try.
     
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  12. Coolant/oil mix ?
     
  13. the last time i seen that colour of oil it had came out of a gearbox that had chewed 3rd, 4th and 5th synchro's. v,brassy looking.
     
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  14. IMG_1626.jpeg

    Anyway, we go off topic - sorry OP:confused:
     
  15. all part of the resto business.
    let it settle for a while then stir it up. nasty. but low millage/ short journey stuff will have a bit of emulsification going on.
     
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  16. It’s all good guys. The pan had been left outside when I was cleaning up and it rained.
     
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  17. Update.
    Bikes painted but I'm not happy with the tank so re-doing it again. In the meantime here's a small teaser.

    zzr painted 1.jpeg

    zzr painted.jpeg

    Finished side panel.
    tempImagek9qtez.png
    I noticed when the clocks where off one of the fixing screws plastic attachments was damaged so I took it all apart and fixed it.
    tempImagebcgKEl.png

    While I had it all apart I took the opportunity to clean the glass inside.

    zzr cleaning cluster glass copy.jpg

    Polished up the road scrapers

    zzr cleaning pegs copy.jpg

    And finally moved the bike to the clean side of the garage to rebuild it. So far new Thermo fitted, system filled (but not bled yet), front brake bled. Rear for some reason doesn't want to bleed so work in progress on that one.

    zzr and ducati getting there.jpeg
     
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  18. you're brave spraying it all like that... not that before ! :)
     
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  19. Well its finally finished. I wasn't happy with the way the clutch was biting so put a new kit in and its driving really sweet as they say.
    IMG_0415.jpeg
    IMG_0418.jpeg
    IMG_0416.jpeg
    IMG_0417.jpeg
     
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  20. wow... that's honestly quite a bit better that I had been expecting... Seriously looks factory new... Amazing
     
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