My 89 Kawi ZX-10 update

[max power]

PM Casper.

[ICEMAN]

thanks

[2talltim]

im not sure why I am issues editing my posts in this thread and not being able to paste any text into this text box.

I have that same issue with IE sometimes I switched to Chrome and never happened again

[ICEMAN]

if that's the case, im not going to worry about it.  I hate having multiple Internets b/c certain sites work and certain don't. Ill see what Casper says and ill go from there.  thx!

[ICEMAN]

I said fuck it and downloaded CHrome since i have a Note 3 i figured i would get my IE bookmarks onto my phone this way.

I apologize that all the pics are missing but I switched FB pages a while ago (accidentally deleted mine and had to start over) so all the links for the pics have changed. sometime ill get them fixed.

here are the latest updates. We bought a house a few years back and I spent some time insulating the garage and building my bike bench. I finally got it all done and spent some time on the bike. I got the motor all cleaned up and put in the bike! lovin the all black look. Looks more like a newer ZX10 compared to an 89. Ill be working on it now that its assembly time! lol.

this is where it was when I pulled it out of the basement of the house we were renting.

bought a table jack to work on the motor and clean it up. This is the new garage before insulation.

for an 89 shes pretty clean!

got the exhaust ceramic coated. They are dusty in the pics.

insulated garage and bike bench built. Motor is all clean and ready to go in! Only took me and my gf to get the motor in. I actually took the bike off the bench and put the motor on the table jack. I then put the bike on my pit bull rear stand the front I put on my car jack with a 4x6 under the wheel. I lifted the front of the bike and used the car jack and table jack to get the motor into place! Was actually pretty damn easy and didn't scratch a thing!!

I LOVE the way it looks now compared to before!!

Edited April 28, 2014 by ICEMAN

[redkow97]

You've almost got a bike there, instead of just a lot of shiny parts!

[ICEMAN]

haha thanks.  Its nice to start seeing this thing come together after 6 years of owning it.  i cant edit my pics in my original post so im going to make a list of the pics here starting from the beginning.  Im going to copy from another forum...

 

 

I bought an 89-zx10 that had been paid down goin 25 on a muddy road, 

no 

mechanical problems, just decorative, lol...  but, im tearin her down and 

turning it into a sport tourer. hard bags and raised handlebars and 

corbin 

seat.  Bought it for 450 bux with only 20K on her!!!

 

Here are the pics from a few years ago when i picked her up and tore her down.

 

 

 

 

 

 

 

 

 

 

[ICEMAN]

 

 

 

 

 

 

 

 

 

[ICEMAN]

 

 

 

 

 

 

 

 

 

[ICEMAN]

 

 

 

 

 

 

 

 

 

[ICEMAN]

Here is a look at what i currently have at the house.

 

 - Engine

 

 - Rims

 

 - Front Suspension

 

 - Frame and Swingarm

 

[ICEMAN]

update...  sorry for the long delay...

 

First Post On This Thread has ben updated with new pics and replaced the red X's, lol

 

woot!!!!  been a while since i last posted.  well last year sucked bc my 89 build was put on the back burner b/c my 05 SV1000s engine blow up.  I bought a wrecked in New York and swapped engines and traded the SV in on a 2006 Yamaha R6 50th Anniversary!!  

 

well then i wrecked the R6 this summer at a track day at mid-ohio.  I am currently in progress of getting the swingarm re-powdercoated and the plastics repainted.  I do have race plastics NOW, lol...  

 

I finally got the ninja motor back to my house, from my parents (thats the only thing ive done to the ninja this year.  when winter comes, something happens and puts the ninja on hold, i think its a sign b/c i learn more and more every day workin at a motorsports shop, so its helping me with the ninja more and more.  When i get the swingarm done, im cleaning up the ninja motor and takin it in and gettin the valves adjusted/shimmed.  the carbs were cleaned last year.  need to replace brake pads and check the pistons in em, and new fork seals.  Then im getting everything clean for powdercoating.

 

im getting the frame, swingarm, rims, triples, and a hundred other little things, lol, all powdercoated over winter and however long it takes.  Then i can start goin somewhere with it.

 

ive finally came to the conclusion of what im going to build.  Im turning the ninja into a sport tourer.  no drag bike or street fighter like i originally planned, racing the R6 on road tracks is SOOOOOOOO much more fun to me!!  So i will be going one up and 2 down on the gearin on the ninja for a better ride.  putting hard bags and a taller shield (if i can find one).  I will be getting the corbin seat also, with the removeable backrest.

 

 

made some progress...

 

here is the swingarm powdercoated!!  it never looked so good!!!  VERY cheap to have done, and the guy does a very nice job!!! and i blasted it myself!!! actually glass beaded...

 

The guy who does the coating lives in Monroe, Michigan.  If anyone is interested, postup or PM me and ill get you his number!! (let him know ICEMAN sent you, thats how he knows me, from another forum)  If anyone wants to see more of his work, join our bike club forum, he has his own section on the forum.  www.tmcf.us

 

alot more to be powdercoated soon!!  he also did my 06 R6 swingarm (i wrecked at mid-ohio and scratched it up!!!).

 

i also just ordered an entire fork rebuild, inner and outter bearings, dust covers, new clips, etc...   i also ordered progressive springs (with a softer spring rate) and i will get the lowers of the forks powdercoated black to match the rest of the bike.  i got softer b/c i want a comfortable ride since im making it a sport touring bike!! 

 

Went to the shop i work at and Springs are in!!  time to tear down the forks!!!

 

before

 

 

after

 

 

R6 swingarm he also did for me!!

 

 

Edited April 29, 2014 by ICEMAN

[ICEMAN]

12-7-08

spent 2-3 hours workin on it. Tore apart the forks and drained fluid. Got to blast and repowdercoat the outter fork tubes and install new Progressive springs after i get them for x-mas and install new seals and bearings (inner and outer). Tore apart upper and lower triple for blasting to be repowdercoated. I need to get to my parents house and bring home some more stuff to disassemble for powdercoating. Need to clean up the engine and get into Schiets Motorsports (where i work) to get the valves adjusted.

 

here is a preview of the powdercoated frame!!  better pics to come!!

 

before...

 

 

AFTER!!!!

 

 

 

pics of all the goodies ive gotten powdercoated.  assembly starting now!!

 

also purchased Continental Road Attack Sport Touring Tires.

 

Parts Blasted

 

 

parts coated

 

 

 

 

 

[ICEMAN]

 

 

 

 

 

 

 

 

 

[ICEMAN]

here is something else im debating on using as a template for paint and such...  paint it all white and use flat black vinyl.  i like the look.

 

 

**UPDDATE AS OF AUGUST 5th 2009**

Bearings assembled into everything, wheels, suspension, rear brake mount, wheels, swingarm, steering stem, etc... everything exterior of the engine has new bearings!!!!! either OEM Kawasaki or All Balls!!!!!

rear shock and dog bones are in the process of being mounted to the frame and swingarm.

waiting on my steering stem to be finished up with the stem and bearings being assembled and i will have a front end to attach to the bike!!! then i will have a rolling chassis!!!!

 

*UPDATE AS OF AUGUST 12, 2009*

 

Got the steering stem bearings together and bottom triple mounted.  Just need to torque down the top bolt to 43 in/lbs. very light pressure.  I got it by hand, to where there is no wiggle, but it spins freely on the bearings without feeling any pressure at all so im gonna leave it there.  

 

Got the frame bracket/engine mount bolted to the frame also.  only have 3 of the 8 bolts, rest are on B/O for a week, but im not torqin it down b/c the engine is not in.

 

i need to grind out some of the powdercoating in the upper triple.  In a spot i forgot to have Jeff plug off.  Once i do that, i will mount the upper triple, and then slide in the forks, front axel, front wheel.  Then put on the clipons and have the front end completed.

 

A bolt im waiting on should be in today or tomorrow to get the rear suspension and swingarm mounted up to the frame!!!!

 

here is my current stop!!

 

 

UPDATE AS OF AUGUST 16th

 

 

 

 

 

 

Edited April 29, 2014 by ICEMAN

[ICEMAN]

 

 

 

 

 

 

 

 

 

 

[ICEMAN]

Got the rear Wheel mounted!!!

 

 

 

 

 

 

 

still need to spend the money on getting the valves shimmed and the clutch torn apart and checked, i bet they are stuck together, if i dont need new fibers... 

been sitting for 3 years. 

already got the carbs cleaned. 

also need to order the Corbin seat with the removeable backrest

also make the hardbag set-up from the FJR or Concourse fit this thing!!

 

Edited April 29, 2014 by ICEMAN

[ICEMAN]

here is the latest pic... yah i know, 5 year project.  but something always gets in the way or i buy another project.  this time i bought 2.

 

 

Got 2 new projects.

 

i bought a 98 CR80 expert to be supermoto'd and i powdercoated the frame, swingarm, triples, linkage, and subframe.  and got 12" rims and a supermoto front fender.

 

Then i bought an 88 CR250.  this just needs 2 fenders, rear brake line, throttle cable, kill switch, thats it.  just getting this running and i will use it as a field burner.  nothing special to be done to this thing.

 

and i sold my 06 50th Anniversary R6. so that monthly payment is friggin GONE finally!! 

and i also got new clutch plates and springs and 15 of the 16 valves needed shimmed. so the motor is good to go!!!

 

update...

nothing else has happened, lol. just blew up my 98 CR80 supermoto. fixin that. finishing up my CR250 to sell. selling both 2 strokes to buy a new CRF150R. R6 is sold.when i get the 150R ill get back on the ninja. im about ready to order speigler stainless brakes front and rear for it tho!!!

[ICEMAN]

FINALLY ive been able to get something else done with this thing.  Its really been pissin me off that i havent had time to do anything on this.

 

I ordered Stainless brake lines from Speigler.  Black lines, Black Banjos, and Black Ends.  They will look tight on the bike!!

 

Got the calipers torn down.  I have new caliper piston seals.  Popped the pistons out this morning at work.  Luckily the pistons are in excellent shape b/c those are expensive.  like 50 bucks a piece.  Watch your fingers if you ever do this, lol.

 

Now i need to send out the rearsets and calipers and get them powdercoated to match the rest of the bike!

 

 

 

 

 

Here are the sweet ass stainless lines!

 

 

 

here is where the bike is currently at...

 

[ICEMAN]

i am rebuilding every part of this bike. with the exception of the motor. I had the valves shimmed and the clutch rebuilt and new plugs, that should be all it needs.

its fun!!

next parts i need to order is a chain and sprocket kit. luckily they make a kit to take it from the 532 size that is is from the factory, and make it a 530 b/c its hard to find 532 chain and sprockets.

and working at a bike shop helps too, lol.

 

Got the calipers, right rearset, brake lever, and some caliper parts sandblasted today.  Also ordered new boots for the calipers.  luckily i can still get them, which means they are prolly used on bikes throughout the 90's.

 

a little bit more cleanup on the calipers b/c i had to tape off the cylinders and slide shaft areas, then clean up and blast the left rearset and off to the powdercoaters!!

 

 

someone will prolly have to finish it and put it in my grave, LOL.  purchased a Hone set off amazon.  3 sizes ranging from 1/2" to 7 o 8" for the same price as the small one at advanced auto.

 

polished up the horns and got the horn brackets ready for powdercoating.  my dremel hasnt been used in years, its getting a hell of a workout now.

 

 

got my speigler stainless clutch lines, new brake pads and cluch and brake master cylinder rebuild kits.

 

then got out the OLD, i do mean old, craftsman drill and started grindin off the rust on the exhaust system.  well, one half of the exhaust system.  This will be getting coated black.  mirror black on the parts you can see when its on the bike, and flat black on the rest of it.

 

my dad bought this drill brand new a LONG time ago.  now its mine and still kickin.  after a few straight hours of runnin it started to cut out so i stopped.

 

 

 

just needed to get the rust and corrosion off, not trying to polish it to a shine.

 

[ICEMAN]

well i got my calipers, caliper slide brackets, and right rearset back from the powdercoaters.  

 

links below the pics are for bigger pics.

 

 

calipers are finally rebuilt!!!!!  all new slide boots on the calipers too!!  its nice when its all fresh and new!!  and i put speedbleeders on the calipers!

 

 

 

WOW. i was able to find a part that they only made for the 88-90 ZX-10 BRAND NEW. a shop in baltimore had one. They have had it in inventory for over 10 years. Its a cover over the ignition and upper triple. Still in the original brown paper wrapping. cant wait to get it!!!!!!! this will be the only BRAND NEW OEM piece on the Ninja, lol. besides bolts and other things that they are still using on newer bikes. im stoked!! the piece i have is in 3 pieces frmo the previous owners wreck. lol. ill post pics when i get it!

 

Got the right rearset assembled with the rear master cylinder and pedal.  cant torque the bolts down until i get the rear torque link put on, im just awiting on a couple o-rings from kawi for that.  so its just finger tight right now.

 

 

 

Polished the original peg.  Keeping the rubber on it b/c theres still a lot there.

 

 

 

[ICEMAN]

did a lot of work tonight.

 

received the part that i ordered that there are only a few left in the country.

 

 

here is the piece

 

 

old and broken on the right.  new on the left.

 

 

rear pegs and brackets assembled

 

 

Rearsets and rear pegs mounted on right side.

 

 

Left side rearset and rear pegs assembled and attached

 

 

Front calipers assembled and installed!

 

[ICEMAN]

few more little things...  had to wait a week for a lot of bolts and other misc things to come in just to do this much.

 

during that week, i got out all the plastic i have for this and cleaned it all up and removed lights and anything else.  I need to do some searching for some light housings for a few things.  i have found most of em.

 

ignition mounted.

 

 

Front stabalizer mounted. The stuff on the tire is paint from the floor stuck to the sticky stuff from the label that was on the tire.

 

 

Torque link mounted up.

 

 

My new chain and sprocket set is in!  OEM was 532, this is a 530 kit.  Sprocket is MASSIVE and heavy.  So is the chain.

 

 

Brand New 1989 Ninja Owners Manual!

 

 

 

ready to start a brand new maintenance record!

 

 

luckily blanks are still available.

 

 

rear brake mounted, ran the new stainless line, and bled.  I love speedbleeders.  Any bike i buy will be switched to speedbleeders.  It was nice to see the rear brake working since the caliper was comlpetely rebuilt.  Just a good sign, saying that everything was rebuilt good and the other 2 should work properly once i finish up the lever and master cylinder and resi.

 

[ICEMAN]

more parts ready for powdercoating

 

 

UPDATE AS OF 8/4/11

 

new cooling fan!  replaces the 4 fin plastic OEM...

 

 

few random pics of some assembly...

 

 

 

got a new camera with a nice lens, i can get real close to something and still get a LOT in the pic!!

 

 

all the shit in the bags in the background is her parents...

 

 

 

 

 

[ICEMAN]

 

 

 

 

UPDATE AS OF 6/6/12

 

we bought a house with a nice big garage so we will be moving shortly (just down the street) and i finalLy got her out of the basement to see the light!!