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12R Refresh Project

13764 Views 148 Replies 12 Participants Last post by  SteveW
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I've been a member of this forum for quite a while, and have read numerous great threads where people have done rebuilds or clean up projects.
Now its my turn!
These days I'm flat out with work, have a 3yo daughter to chase around and another baby due in about a month - I'm very time poor...
So I decided - I need a new project! 馃槅

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Over the years I've accumulated a heap of spare ZX12 parts, just because they're becoming rarer and prices for good parts is just going up.
Last week I spotted a 2004 B3 advertised on Marketplace - not running and no registration, a bit rough around the edges with a "fried ECU". Well good for me, I happened to have a spare ECU and key/lock set in the shed. The AUS/EUR 2004-2006 ZX12's have a built in immobilizer, so you cant just swap the ECU out and have it running. You need a matching key for it to start up.

I met up with the seller, it seemed as if someone had lost the keys in the past and an attempt to hotwire the bike was made.
First I installed the battery/tray from my 06 bike.
So I plugged in my spare ignition switch and ECU, cluster turned on, but there was still a fault light flashing at me.
I worked out quickly that the original ECU wasnt fried (it was in a box) but what was fried was the immobilizer antenna unit that sends the key information back to the ECU. This had been removed and opened - I'm guessing as part of the hotwire job.
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I pulled the immobilizer antenna unit off my 06 bike and then the immobilizer fault codes stopped and the fuel pump primed. I wasn't too keen to fire it up yet as the fuel was pretty stale, and I was unsure what the tank condition was actually like.
Looking over the bike, I thought even if the motor was no good, I could probably make my money back by parting it out.
Its got a full Yoshimura exhaust system, Power Commander, carbon fenders, good Radial forks - etc etc etc
Title checked out ok, so after a bit of bargaining the bike was now mine.
I checked the oil and coolant, disconnected the Power commander, installed the fuel tank from my 06 bike and fired it up.
Seemed to be nice and smooth, no strange noises from the motor. A win I think!

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Got it warm and dropped the oil. Also noticed the cam cover gasket is leaking a bit and making a mess, possibly the cam position sensor o-ring.
It had a 0004 oil filter - I haven't bought one of these since 2010, so that tells me the oil probably hasn't been changed for a very very long time.
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I had a look in the Oil for glitter, or any indications of metal - nothing visible to my eyes. I'll probably cut the filter open later for a look.
Fitted a new 0008 filter, sump bolt gasket and some fresh Aussie Penrite 10w-40 Synthetic Oil
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While I was doing this I decided to remove a bunch of little LED "show lights" that were on the bike. The fuse box was missing a couple fuses so I replaced them too. Tail light fuse was blown - strange...
I also pulled the Genuine air filters out, and checked the condition of the air box. Pretty clean. Replaced the filters with some cleaner low use OEM filters that originally came off my brother's old ZX12. Only other option I have here are BMC Race, but dont think this needs them yet!

Went to fire the bike up with the new oil. No go!
What? I hadn't done anything besides remove the LED's. I checked a few things, and nothing was out of the ordinary.
Fault code was showing Cam Timing sensor. Pulled the sensor out of my 06 and swapped them. Still no go.
Checked the wiring diagram in the Workshop Manual. Pin 12 on the ECU.
This is what I found -
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Obviously part of the hotwire job. Tried to inject power from the tail light to the ECU - this explains why the Tail light fuse was blown.
Reinstalling the fuse was sending a dodgy voltage signal to the ECU. I cut the wire and the bike started again!

Put the original Cam pos sensor back in with a new O-ring.

Got it warm and just checked the TPS voltages.
This handy adapter from NinjaYorkie makes an easy job of it!

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Not much else done. I've got to come up with a bit of a plan for it.
Fuel tank and fuel pump is probably the highest priority to get checked out.
But I'm thinking for now, change the leaking cam cover gasket - while I'm at it check valve clearances and change spark plugs and the figure 8 gaskets.
Radiator and coolant flush while I'm at it.
Needs a new battery and tyres and I've got a few little parts to chase up.
Then probably fork oil, brake fluid, and check all bearings.
Besides the Chinese fairings, its in pretty good condition. The carbon front fender and rear hugger are pretty nice.
I do have a complete full set of genuine 04 Candy Thunder Blue fairing's I can put on this bike.
It will make a nice clean street bike. My brother is already talking about buying it off me - he sold his 2006 ZX12 a couple of years ago when he moved overseas for work, but due to Covid he returned home and is missing his old bike. I'll have a think about that...

Stay Tuned!
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Again, great McGyvering!


Btw Don, what radiator hose kit did you end up putting on your 12?
I'm looking at the AS3 kit
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I unbolted the front calipers and spun the wheel - didnt spin for long..
Bearings and seals were already on my to do list.
Picked up some good quality NSK VV bearings. Front hub seals are ZX10 part number, same size, just newer? Thought I'd just try them.
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Wheel off, old seals out. Not the original bearings or seals. Didn't matter too much I guess but seals were 7mm wide instead of factory 5mm .
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More McGyvering here - I learnt this trick from one of NinjaYorkie's posts..
Take one dynabolt
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Expand the end of it into the bearing, and knock it out from the opposite side.
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Clean enough. Knock the bearing into this side first and seat it on the lip. Install circlip against it. Then from the other side insert the spacer tube and knock the other bearing in.
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New bearings and seals done
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The wheel: Red valve cap has already made its way to my daughter's bicycle..
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Not entirely happy with the condition of this rotor. Would be a bit lighter than OEM, its thinner too.
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A little while ago I scored a set of very low mile and great condition rotors from CMG, which came from his "Winter Blues" project bike. Think I might use these. Or I've got a set of 320mm's from a B1 I could use with some caliper spacers.
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Have some more bits from the ZX10 parts bin on the way. Right angled valve stem. Already fitted one to my B6 last time I had a new tyre fitted.
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Daughters bike has to look good too!
Nice work. The Braking rotor won鈥檛 clean up?

cmg
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Good tip from Ninjayorkie!

I bought the AS3 kit too. I had to reuse one of the oem hoses from I think the radiator overflow to reservoir tank as the AS3 hose was too thick and would push out on the side fairing. You'll find out when you fit them. Otherwise seem to be a good kit.
Daughters bike has to look good too!
Nice work. The Braking rotor won鈥檛 clean up?

cmg
Not sure what I can do about the gouge in the rotor.. I'll look into it.


Good tip from Ninjayorkie!

I bought the AS3 kit too. I had to reuse one of the oem hoses from I think the radiator overflow to reservoir tank as the AS3 hose was too thick and would push out on the side fairing. You'll find out when you fit them. Otherwise seem to be a good kit.
Price of the AS3 kit looks good. Did you buy the clamp set too? Thanks for the info!
I think I did.
Worth buying the clamps anyway really
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The Braking rotor won鈥檛 clean up?

cmg
Weights:
OEM 300mm, 6mm thick (min 5.5mm) - 1620g
Braking 300mm, 5mm thick (min 4.25mm) - 1415g
OEM 320mm, 4.8mm thick (min 4.5mm) - 1385g
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Just need a few shims to use the 320s. Nice

cmg
3
Pulled off a bit more to do some cleaning. Also swapping the rear subframe with one I've got in better condition.

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Thought I'd grease up all the bearings while I'm at it. 04-06 dont come with grease nipples. I had one from an 03 that I've put in instead.
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Pulled the rear wheel out. The axle wouldnt budge at all! I had to knock it out with a drift and a fairly solid hammer!
Aftermarket bearings have been installed in the past - I cant even turn these at all by hand!
Theres a chance I tightened them up when knocking the axle out, but oh well - definitely getting swapped with the new NSK's I bought last week.
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I wonder why the later models didn't have grease nipples?
Thats odd, mine is a B3H (2004) WITH nipples.

Bear
I wonder why the later models didn't have grease nipples?
Cost cutting? People banging the nipples on speed humps?

Thats odd, mine is a B3H (2004) WITH nipples.

Bear
Interesting, maybe they had a changeover? This one is October 2004.
My 06 definitely doesn't have nipples and the parts diagram reflects this.

1 job now made easier!
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Checked parts diagrams, B4H and B6F don麓t have nipples.

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Bear
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Ended up pulling the swingarm and checking the bearings and seals. Changed out the RH seal only.
Rear wheel and carrier bearings with seals changed too. Everything else around there cleaned up while it was apart.
Local shop that did my injector service (5 mins down the road) lent me the socket to tighten the swingarm shaft lock nut. Awesome guys.
Gave the carbon hugger a clean and put it back on. Looking sweet.
Making progress, hopefully my other Kawasaki spare parts from Japan arrive this week so I get a few things sorted

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Street bikes don't really need those zerks. The suspension has very little travel and those bearings should be inspected/repacked anyway rather than just blindly pumped full of grease.
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Yep I thought that too with the hugger, well finished off.
Street bikes don't really need those zerks. The suspension has very little travel and those bearings should be inspected/repacked anyway rather than just blindly pumped full of grease.
Hmmm.. Well at least I've checked out the condition of the bearings and the sleeves. The bearings in the earlier unitrak I reinstalled were in better condition than what came off the bike - They were dry with bits of plastic flaking off the insides of the rollers.
Really good looking hugger.


cmg
Yep I thought that too with the hugger, well finished off.
Cheers guys
Hmmm.. Well at least I've checked out the condition of the bearings and the sleeves. The bearings in the earlier unitrak I reinstalled were in better condition than what came off the bike - They were dry with bits of plastic flaking off the insides of the rollers.
Yep, the decision to go with plastic cage bearings instead of cageless bearings is actually a move in anticipation of little/no lubrication or maintenance!
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Yuk..
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Pads not too flash either
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Everything cleaned up, Pistons polished up ok. Just waiting for a seal kit to arrive from the local dealer.
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Factory giant under tail flap has appeared - I still need to have the bike inspected for registration once I've got it going again. Also put a stock tail light in, instead of the smoked LED tail/flasher/combo
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