Some Build Progress

As I reflect on my progress of the ZX7RR build, it's interesting to note how I've spent my time and effort. Between daily forages through classifieds, picking up packages/parts, and dealing with shit that don't fit, I've really only spent about 10% actually with the bike.

Fitting the rear wheel for example should be something that isn't too difficult... but the first problem I had was the spacer which connected the cush drive to the sprocket carrier. It was made from some grade of steel that my little lathe couldn't cope with. So that had to be outsourced while everything else was put on hold.

Old spacer on left, new spacer on right

A week later with the steel spacer finished, I started to mount the wheel so I could measure it up on the swingarm for spacers. When I originally picked up the Braking/OZ wheels it came with a 525 rear sprocket. However my bike used 520 sprockets which meant the 525 needed to be replaced in order for an accurate spacer measurement to be taken.

Cleaning up the sprocket carrier

520 sprocket mounted and ready to go on the wheel

With the sprocket sorted out, I had some rough measurements for spacers and pulled out the lathe.

Boring out a section of aluminum bar stock

Some more cutting later

Sprocket side spacer

Rotor side spacer

My ghetto depth stop

I re-made the rotor side spacer a few times but in the end things worked out nicely.

Now my wheel was on the bike. It was centered, the chain lined up, and everything looked good in general. Onwards then to the rear caliper.

I made several different sized spacers for the caliper but it kept rubbing against something. I couldn't figure it out for days until I looked at the wheel hub! SCRATH CITY!!!!! OMG!!!

scratchy scratchy ouchy ouchy!

It turned out that the ZX7 used a double piston rear caliper while the ZX10, which is what these wheels were designed for, used a single piston caliper. The wheel hub required a much smaller caliper.

After some queries on the ZX7 Owners Club and some time with Ronayers micro fiche collection, I learned that I needed to swap calipers and caliper brackets with one of the following bikes:

• 2000 - 2004 Kawasaki Ninja ZX-6R 
• 2000 - 2003 Kawasaki Ninja ZX-9R
• 2003 - 2006 Kawasaki Z1000
• 2005 - 2008 Kawasaki ZZR600

I managed to find a caliper bracket for a first get 636 courtesy of local Kawasaki Enthusiasts, Stunters Inc. If you own a Kawasaki and are located in the Greater Toronto Area, there's no excuse not to get hooked up with these guys.

One of the first things I immedately noticed was that the 636 caliper bracket was pretty light. In fact my digital scale showed almost 2 pounds in weight saved! And that was unsprung weight.

ZX-7 caliper bracket

ZX-636 caliper bracket

Not only was the 636 bracket lighter, but the bracket mounted the brakes above the swingarm whereas the ZX-7 bracket mounted the caliper below the swingarm. The relocated caliper is better protected from road crud and easier to remove/install. Predictably though, a new bracket meant new spacer dimensions were required. Because the 636 caliper bracket was thinner than the ZX-7 caliper bracket, I needed something longer.

I decided that a temporary spacer to fill the gap will do for now. Once I had the dimensions worked out exactly, I'll make a one piece unit.

New spacer

New spacer + old spacer

New spacer + old spacer

Perfect fit. Now all I need is to find a caliper

So that's the state of my rear wheel at the moment. It's on there but there's still work to do. Between lathe sessions and waiting for parts, I received some goodies from Sportbike Track Gear for my front end.

Now that I finally had my clipons, I mounted all my controls and took the bike out for a quick photo shoot.