Ive been building my 2001 ZR7s on and off for the last 6 months...i thought i would share the building of this bike as i work on it...so far, all the parts i have installed on the bike I either had sitting around, customer take off parts that were not wanted, parts that have been sitting around the shop and others that i simply gave my labor in compensation...when i bought the bike, i never planned to do all this....i got it from a dealership that i was working...a customer was trading it in a the dealership....the dealer only was giving him $500 for it toward the purchase of a new bike....it has 9955 miles on it, had blown forkseals, and the carbs needed work...the bike had been lightly dropped on the left side and is 100% stock....i got it for $700....then...walkn through the bikes that have been abandoned by customers throughout the years, lookn for a part for a customers bike, a saw an 06 zx636 that has been there since 07...for some reason i my eye caught the swingarm pivot bolt....i thought to myself..that looks like the same size as the zr7s....hmm....thats all it took...now i work on the bike as a release...a way to just have fun...try different ideas...see what i can do....so as i post pics and update please give me your opinions, ideas and whatever else more....IMG_20120501_161003-1.jpgIMG_20120502_222640.jpgIMG_20120511_225742.jpgIMG_20120511_225812.jpgzr7 damper mock up.jpg

the bike is a little further along than whats pictured....im heading to the shop now....ill take some pics as it sits today...look at my signature for whats on the bike already

IMG_20120723_211244.jpg 07cbr1000 front fender, 320mm rotors from 03 zx9...(99 zx9 had 300mm) IMG_20120723_205801.jpg gauges lowered one inch IMG_20120729_120258.jpg mounted cbr1000 damper to original.. IMG_20120720_190914.jpg the subframe cut down to fit the zx9 tailsection

Curious whether you had to replace the triple clamp on the zr-7 when you put in the new front forks?
Also how much lower or higher are the new forks?

[QUOTE=zr7_interloper;768605]Curious whether you had to replace the triple clamp on the zr-7 when you put in the new front forks?
Also how much lower or higher are the new forks?[/QUOTE
Actually I installed a 99 zx9 front end....I pressed the steering stem out of the zx9 lower and spun it down on a lathe until thestock zr7 bearings fit the stem and were located in the proper position...I had to get creative with the top triple clamp.....its actually the zx9 top clamp flipped upside down....I spent a lot of time on the Bridgeport shaping it....the reason for the upside down install is that allowed the top clamp to sit lower on the stem....the top clamp is recessed where the nut is....as far as the fork height...I have the bike lowered a bit but I'm not gonna set them until finish making the exhaust and: I know the ground clearance......the forks themselves are just a littles shorter but are stiffer and have compression and rebound screws as well as pre-load...i was hoping to find a set of inverted forks...but this complete front end cost me about 3 hours of labor on an 06 R1

about a month ago, i found an add a on craigslist saying "parting out zx-12"...i called, asked about the ram air duct work...the guy said he would sell me the ducts, but the inlet he didnt want to seperate from the front cowl....the other day, texted him, he still had the parts....i got the front cowl, headlighhts, turnsignals, windscreen and ram air ducts for less than 100$.....last night I mocked up the inletIMG_20120802_195633.jpgIMG_20120802_195538.jpgIMG_20120802_195619.jpg

I'm keeping a keen eye out for this one when it's finished

IMG_20120803_150803[1].jpgIMG_20120803_155620[1].jpgIMG_20120803_155634[1].jpgits gonna be a bit....still have a lot ideas....like this one i got tonight...i was doing a crash repair on a cbr600rr....the headlights were just being held on by twisted wire..so i cut them off and took a look at the reflective lenses inside...i looked over at the zr's headlight....looked back at the cbr headlight...got out the heatgun....pulled the covers off and removed the inner reflective lens....now, on the cbr600...left side is low beam, right is high beam....the bulbs are the same...the differance is the way each reflector is shaped...im thinkn of trying to put both reflectors behind the stock clear lens...my original headlight is allready hacked all up.....when im done with all the set up and is happy with what i see, then i will find another hedlight and make it to what i finially end up with....

youve got access to all sorts of goodies to make this one wicked zr7

yea shortlife....im lucky in that way....im working at a small very busy independant shop....we work on everything...harley, the big 4, triumph and whatever comes in the door.....and its only me and my friend wrenchn in the shop...seems like 12 hour days are normal anymore....anyway...when i look at a bike that comes in for work...im lookn at what would look good on my zr7...or even my fj1100 that im going to get running soon...its like, choosing parts from every brand out there...its cool...and about my job...its not really work...its hanging out with my friend, fixn bikes, working on our own bikes after 7 start having a beer at 701..get the welder, or go over to the lathe or bridgeport or go diggin through his parts loft...

whats the story on the rearsets? what bike were they adapted from and was it hard to modify it to fit?

Originally Posted by MonkeyBiz

whats the story on the rearsets? what bike were they adapted from and was it hard to modify it to fit?

The rearsets are of a R6s model (03 style)....the bolt holes lined up perfectly...i put 7.5mm spacers to bring them out..because of the upper brace on the 636 swingarm...the brake side..straight bolt up...the shifter side im still playn with...i have a suzuki shift pedal for it that works, a shaft arm from a zx12 that is perfect....what im running into is a adjustment rod...i can make it none adjustable very easy but i would perfer the adjustability...i have time to think about it....but the rear sets gives u a great feel....in my opinion...they are in a very good position

Originally Posted by Bike Tech AZ

The rearsets are of a R6s model (03 style)....the bolt holes lined up perfectly...i put 7.5mm spacers to bring them out..because of the upper brace on the 636 swingarm...the brake side..straight bolt up...the shifter side im still playn with...i have a suzuki shift pedal for it that works, a shaft arm from a zx12 that is perfect....what im running into is a adjustment rod...i can make it none adjustable very easy but i would perfer the adjustability...i have time to think about it....but the rear sets gives u a great feel....in my opinion...they are in a very good position

that's awesome! cause the left side hangar/bracket cracked on mine where the peg mounts. instead of paying 100 bucks for a used one on ebay i could pick up a pair of adjustable ones for an R6 now for a lil bit more money.

Originally Posted by MonkeyBiz

that's awesome! cause the left side hangar/bracket cracked on mine where the peg mounts. instead of paying 100 bucks for a used one on ebay i could pick up a pair of adjustable ones for an R6 now for a lil bit more money.

yes u can, but you are going to have to use a different shifter because on the R6 the shift rod comes out the top, not below the footpeg...but go for it...its worth it

What did you have to do to mount the swingarm and shock? Or was it a straight bolt on affair?

well...it hasn't been a straight bolt on affair...the install of the swingarm itself was actually pretty easy... the pivot bolt is the same diameter on both bikes...the only thing i had to make was a spacer on the rh side of the swing arm to make up the gap to the frame...The challenge is with the shock and linkage...The shock mount on the frame is the first thing...with the (long) zr7 shock, it makes the back of the bike sit like a dirt bike...with the shorter (but fatter) zx636 shock it brings the shock in contact with the swingarm because of the location of the mount is to far forward...so i welded on a new shock mount onto the frame...(which is where the battery used to be)....next problem was the linkage and dog bones...look at the dog bones on the zr7...they are curved...the curved dog bones dont make it around the 636 shock...Grrrr...I used the knuckle from the zr7, cut-down some hardened collars and had stock dog bones off of I dont know what (have a pile in my box from working at the drag bike shop for years) and got it all to work...This install of the swingarm and shock was the first thing that i did on this bike when i got it...it all snow balled from there...and when i did this install, I was working at a huge multi-line corporate nazi dealership...now I work at a small but very busy repair/custom shop...the shop im at now has better welders, plasma cutter, lathe/bridgeport machine and more....so actually, im going to cut out the shock mount i first installed a remake it...one day....lol...after i get done the front-end