How to build a ZR-7e(s) - Page 3

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How to build a ZR-7e(s)

This is a discussion on How to build a ZR-7e(s) within the ZR-7 Performance Upgrades forums, part of the Kawasaki ZR-7 category; In regards to my fitment of the zx6r forks. I got the sleeves and a spacer made up as per the dimensions stated in this ...

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Thread: How to build a ZR-7e(s)

  1. #31
    Rising Star Wado750's Avatar
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    In regards to my fitment of the zx6r forks. I got the sleeves and a spacer made up as per the dimensions stated in this thread. When time came to mount the wheel I found the wheel was not central between the forks and was 1mm too far towards the speedo drive end. It may not sound much and I didn't think it would make much difference until I tried to mount the brake calipers. One caliper would have needed to be shimmed and the other was a tight squeese to mount on the fork with the caliper on the disc. So by spliting the difference I would need to take off 0.5 mm of the original ZR7 spacer and add 0.5mm to the speedo drive spacer that I have made up.

    Also I found that the zx6r calipers were difficult to get onto the ZR7 rotors. If the brake pads were new then if would have been frustratingly difficult. I looked at the specs for the rotors and the ZR7 ones are a whole 1mm thicker which would account for that difficulty. So zx6r rotors and new brake pads are on order.
    Last edited by Wado750; 06-16-12 at 03:04 AM.
    Neil
    Yamaha FZ8S


  2. #32
    Site Elder pattonme's Avatar
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    zx6r is a very generic term and means nothing. It would help your fellow board members out if people were specific (eg. zx6e, zx6f, zx6h3, etc) because those suffixes actually mean something.

    I don't remember installing calipers to be that much of a pain just as long as the pads were all the way back. Might help to slightly bevel the leading edge too.

    pics of my bike can be seen at http://www.riderforums.com/zr-7-sale...tml#post188423
    Last edited by pattonme; 06-16-12 at 06:56 AM.

  3. #33
    Rising Star Wado750's Avatar
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    To be honest I dont know what you are talking about with zx6e and zx6f? We never got those models in Australia but im assuming they are the same as zzr600 and zx6r that we get here. The forks were from a 95 model if that helps.
    Last edited by Wado750; 06-16-12 at 05:57 PM. Reason: funky internet
    Neil
    Yamaha FZ8S


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  5. #34
    Supreme Being zr7_interloper's Avatar
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    Quote Originally Posted by Wado750 View Post
    To be honest I dont know what you are talking about with zx6e and zx6f? We never got those models in Australia but im assuming they are the same as zzr600 and zx6r that we get here. The forks were from a 95 model if that helps.
    Not sure about Ozland, but I think in the US, the zx-6f were for the years 1995-1997 (also known as zx-6r(f))
    The zx-6e (also known as zx-6r(e)) were produced in earlier years (1993, 1994) but were also being produced during 1995 through 1997 and beyond. They kinda overlapped models.The zx-6r(f) was the supersports model while the zx-6r(e) was just their regular sports model (when both models were being produced at the same time). That's my understanding but I could be wrong

  6. #35
    Rising Star Wado750's Avatar
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    I did some googling and I understand more. The one you guys call the zx6e is a zzr 600. The one you call a zx6f is a zx6r 95 to 97 model. We tend to deal with years here when ordering parts. E.g. You would say to the parts guy. I have a 99 zx6r that i need brake pads for.
    Neil
    Yamaha FZ8S


  7. #36
    Rising Star Wado750's Avatar
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    I'm going to re-try fitting the wheel again tonight. I've re-read all the posts in this thread and if 2 people have done this mod with the 4mm spacer then why am I different. I have a set of vernier calipers and I have confirmed that the spacer I had made up is 4mm wide.

    The setup as viewed from the front is:

    ZX6F Fork---original ZR7 spacer-----original ZR7 wheel------ZR7 speedo drive----4mm spacer-----ZX6F fork

    Before tightening up the axle there is a few mm gap between here----------------------------><-------------- (the 4mm spacer and fork leg)

    Update:

    I have measured twice in two different spots and I am 1mm too far to the right as viewed from the front. The ZR7 spacer side has the disc rotor central in the calipers and the right caliper is off central by 1mm. So I might get a 5mm spacer to replace the 4mm spacer as it does appear that the fork is bending slightly to meet the spacer. Any body have any thoughts?
    Last edited by Wado750; 06-18-12 at 05:02 AM. Reason: update
    Neil
    Yamaha FZ8S


  8. #37
    Rising Star Wado750's Avatar
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    I decided to get 2 more spacers made for between the speedo drive and fork leg. They are going to be 5mm and 6mm. I should get them tonight for a test fit, so I can measure if the wheel is central. If that is successful then I'll take the forks out to repaint the fork legs. I have new disc rotors and brake pads for the new brakes to install. I got 95 zx6r rotors, same bolt holes as the zr7 but they are 1mm thinner and have a larger offset by 0.8mm so the calipers may need to be spaced out to centralise them on the rotor. Also I will put a seal kit through the zx6 calipers and paint them before final assembly.
    Neil
    Yamaha FZ8S


  9. #38
    Site Elder pattonme's Avatar
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    EVERY market in the world has a ZX6R or ZZR600. Indeed just since 1990 the "ZX6R" term applies to a dozen different models. That's why I said it means absolutely nothing. It is a marketing term, nothing more. When you go to the parts counter you the clerk will ask you for what model. If you say "ZZR" he will give you an exasperated look and ask you to tell him what year. Only then can he know what actual model (zx6e1-5, zx6f1-3, zx6d, zx6[a-h][1-9] etc) you actually have. There might be some skew on which markets had which model for any given year but a ZX6e4 is the same the world over.

  10. #39
    Site Elder pattonme's Avatar
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    There should be very little 'gap' when you put it all together WITHOUT tightening the axle. Maybe a sheet or two of paper thickness. Sound like you need a 5mm and 5.5mm to test.

  11. #40
    Rising Star Wado750's Avatar
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    The task is now complete and wow what a difference to braking and handling. It should have came like this from factory.
    Items used:
    ZR7 wheel spacer
    ZR7 Axle
    ZR7 Wheel
    ZR7 Speedo drive
    5mm spacer
    ZX6R(F) brake calipers
    ZX6R(F) brake disc rotors
    ZX6R(F) forks
    M6 washers to centralise the ZR7 mud guard (2 on each mounting point)
    M10 washers to centralise the brake calipers (1 on each mounting point)
    2x sleeves with inside diameter of 23 and outside diameter of 25.

    Once I found the correct spacer size I glued it to the speedo drive to make it easier to mount the front wheel. Also I'm going to get a ZX6R(F) front mud guard as the ZR7 one doesn't sit right. You do have to drill new holes for the rearwards mounts but you have to make a choice between centralising it over the wheel or making the gap between the fork leg and the mud guard paralell. I choose the latter. See below. I'm still bedding in the brakes.

    IMAG0098.jpg
    Neil
    Yamaha FZ8S


  12. #41
    Site Elder pattonme's Avatar
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    congrats on a successful upgrade.

  13. #42
    Supreme Being zr7_interloper's Avatar
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    Wado, that looks fantastic!
    Please give us updates on how the mods are working out.

  14. #43
    Rising Star Wado750's Avatar
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    Quote Originally Posted by Wado750 View Post
    Also I found that the zx6r calipers were difficult to get onto the ZR7 rotors. If the brake pads were new then if would have been frustratingly difficult. I looked at the specs for the rotors and the ZR7 ones are a whole 1mm thicker which would account for that difficulty. So zx6r rotors and new brake pads are on order.
    I found out the the reason I couldn't get the calipers on is that I didn't push the pistons all the way in. I'm guessing that ZR7 rotors would have worked.
    Neil
    Yamaha FZ8S


  15. #44
    Supreme Being zr7_interloper's Avatar
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    Yeah, when I replaced my brake pads with new ones, they were hard to fit over the calipers.
    I made sure that the pistons were well cleaned with wd-40 and then with contact cleaner.
    With the pads in place, I used a large flathead screwdriver to force them open wide.

  16. #45
    Rising Star tmoons's Avatar
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    OK, I've read the previous posts, did some looking around and came to the following 2 parts.

    A set of calipers, and a complete fork (no wheel, fender or axle as far as i know). (the calipers came off the fork!)

    Would this be interesting to purchase to do the conversion, or would it mean a lot of fidling with bushes and spacers (in order to use the original wheel?)
    The parts come from a 1995 Zx6r
    digiads_motorbike_ads_136824_1.jpg

    The calipers are 4 pistons each
    The springs are upgrades ones (in the fork).

    Any suggestions are more than welcome.


    Calipers:
    mijnklauw.jpg
    Fork:
    mijnvork2.jpg

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