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Discussion Starter #1 (Edited)
I don't post alot on this forum. Usually I keep my fingers off the keyboard so I can read what you all have to say and learn some stuff (alot of stuff) in the process. I'd like to share with you all my build. It's nearly complete now but I'll start at the beginning so you guys can see it all develop (mistakes included). Before I start I want to thank several people for their advice, even if none of them know they gave me any. KZ Scott, Almost Les, Ridge Racer, Color Me Gone, 1990sss10 , engineerrol, DRP and pretty much everyone else on the forum.

Some of you may have seen this on another forum. I kept a thread there as I was building it to keep me motivated to get it done and not sit in the garage for another year.
And here we go....
I'm the original owner of a 2000 ZX12R that I bought in April 2000. I saw pictures of the bike in the fall of 1999 and fell in love with them and then when I saw them in person in Gainesville,Florida at the spring Prostar race and then again a couple days later at Bikeweek in Daytona I decided I had to have one. When I got home from bike week I immediately put my 98 ZX9Rand my 87 GSXR 750 up for sale.









They both sold to the first person that looked at each one. I took the money and went & bought one of the first green ZX12R's that arrived in Southwest Ohio. The owner of the dealership is also an old friend so he gave me the list of bikes coming in and let me pick the VIN number I wanted. I rode it and raced it in various forms over the years.
That's me giving it the business:

 

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Discussion Starter #2
I added different stuff to the bike over the years and a few years ago I started a turbo build. Now I'm finishing that build and I will be riding the beast this summer.









If the header looks familiar to some of you it's because it started life as a stock ZX12R exhaust.
This isn't an off-the-shelf-kit. I designed it in my head and my brother and I fabricated it.He's certified in every form of welding there is except for underwater (we have a cousin that does that). I'm an aircraft mechanic by trade (24+ years and counting) and my specialties are structures and sheetmetal fabrication. I'm going to try my best to keep this updated as things progress, so stay tuned.
 

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Discussion Starter #3
It will see the dragstrip, but it has to completely and fully be able to perform on the street as well. All signals, lights, horn,etc must work as advertised. Basically I want a clean looking sleeper.

All the additional toys will be hidden inside the bodywork so the average Joe will not notice anything when looking at it. To the trained eye or anyone who knows ZX12's it will be obvious that things were done to it but it won't necessarily be obvious as to exactly what was done.







Oil cooler was relocated:


 

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Discussion Starter #4
The ZX12R's always had a very "iffy" fuel pump. They weren't designed to handle much horsepower over stock so I upgraded to a Walbro pump. It's not really impressive to look at. If you didn't know better you'd think it was still a stock unit except for the bigger pre-filter (sock).



While I'm addressing weak links, the clutch is a timebomb in a 12. The stock basket will explode eventually on the dragstrip or even if abused on the street. That's why I went with Muzzys clutch kit:



and a billet clutch basket from Falicon:



 

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Discussion Starter #5
Several years ago I stretched the swingarm 4 inches and this forced me to remove the stock undertail. I made a new one out of aluminum but it was flat and the rear tire would hit it on a hard launch. I modded it with a recess in it to enable hard launches without hitting it anymore:





In the pictures you can see where the tire used to hit. I will paint it with the rest of the brackets I still need to fabricate. I need to brace the pan the oil cooler sits on and make a bracket for the scavenge pump to mount. I also have to mount the new fuel pressure regulator as well. That will be a nightmare I'm not looking forward to.
 

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Discussion Starter #6
I spent today figuring out the fuel delivery and return system.
I'm using a Walbro pump to feed this thing and although I'm cheaping out right now and using the waste gate and blow off valve springs to control the boost, it won't stay that way. So I need to be able to feed the horses when they want hay. That's why I'm using an Aeromotive fuel pressure regulator to maintain fuel pressure. These things use AN fittings to connect it to the fuel system and the ZX12R uses 5/16" rubber fuel line so I needed to connect the two. I went to Jegs (they're right down the street from where I work) and bought braided line and fittings to make the connections. I also went to NAPA and got some high pressure rubber fuel line for that side of it. I'm locating the FPR on top of the valve cover due to space restrictions everywhere on this bike and running the lines to connect everything from there.









It looks sloppy right now simply because nothing is completely tied up. Trust me, when it's done everything will be secure and you won't see anything I don't want seen. As you all can see I still need to make the mounting bracket for the FPR. It's on my list and I plan to have it done and mounted by the end of next weekend.
 

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Discussion Starter #7
This beast still has the dry nitrous system installed. I'm keeping it in there for now.









It's also sporting Muzzy velocity stacks. I don't need them for boost containment at the moment but I might down the road....:evil
 

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Discussion Starter #8
Here's a better look at the pan the oil cooler sits on:



The oiler cooler itself is originally a power steering cooler from a 1999 Ford Super Duty pickup. I cut the hose ends off and my brother welded AN fittings on. We also reversed the angle and orientation of the cooler so it sits lower and is angled for max airflow across it from the now unused ramair snorkel.



As you can see the cooler needs some trim work done. That's another project for this week.

The other part of the oilcooler relocation is the Muzzy oil filter relocation kit:









It provides the mount for the oil filter feed and the block off for the original oil cooler. You supply the filter,cooler and all oil lines. The good part of this kit is the extra feed line that I used for the turbo oil feed. You just need to run an in-line restrictor to keep oil volume down. Otherwise you can blow the seals in the turbo. That will make for a bad day.
 

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Discussion Starter #9
Scavenge pump is physically installed but not wired in yet.I'm waiting to do all the wiring in on shot. I still have some electronic goodies to install and 3 gauges, so I'll wire it all at once. Here's the pictures of it:





I will slide the rubber scavenge pump hose in a heat sleeve next weekend. I got the wrong size on my previous trip to Jeg's so I have to wait until later this week to get the right size.

While laying out the brackets I need to fab I put some of the bodywork on the bike to make sure everything will disappear once it's all together. Here's some shots of that:





 

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Discussion Starter #10
Here's my dash/triple clamp layout. There are 2 switches on the right side of the ignition switch. One is for arming the nitrous and the other is for arming the air shifter. The airshifter, when armed, uses the horn button as the shifter. The nitrous, when armed, uses the starter button as the nitrous button. You can see the toggles in the next photo. The red button on the left, just inboard of the left controls, is for the air compressor to fill the air tank. The swing arm is pressurized and used as the air tank.The bracket that has "MPS" on it is the kill switch for drag racing. The last photo shows the air pressure gauge for the shifter and the Autometer shift light.







 

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Discussion Starter #11
Here's pictures of today's progress:



FPR bracket















Chainguard











 

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Discussion Starter #12
Yesterday and today's progress:






The chain guard is trimmed and painted. Ready to install.
 

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Discussion Starter #13
I stopped at Jeg's on the way home from work and I went to my favorite Kawasaki shop. I've got a bunch of stuff to do!












I'll be busy today. Installing the lock up clutch spacer, heat shield for the scavenge pump line, chain guard, FPR & mounting bracket, radiator (it's currently temp installed), oil cooler and quite a few other things! Yaaaaaay!
 

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Discussion Starter #14
Here's a summary of yesterday's progress.


Oil cooler is permanently installed.









The scavenge line is permanently installed with the thermal shield installed.





FPR is installed. I put rubber between it and the bracket it sets on for anti-vibration purposes.





I also did alot of minor maintenance stuff on the bike. I went around it checking torques on everything from engine mount bolts to engine covers, etc....
 

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Discussion Starter #15
I had two setbacks today. One was expected and one was completely unexpected.
Once I figure out what I need to do to resolve the unexpected one I'll post about them.
 

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Discussion Starter #16
The expected one is a ducting issue. I'll post pics later. The unexpected is the shifter shaft is moving too much. I might have to drop the engine to fix it.:squint

I'm trying to figure out what's messed up.
 

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Discussion Starter #17
The expected issue is with the turbo piping. I had a different opinion of how to route it but was talked into the way it was routed. Now that I have the front fender on you can clearly see the issue.






















I've already selected the parts I need to correct this. Now I wait for the UPS guy.



I'm going to rotate the turbo like it is in the photo and reroute the tubing.



 

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Discussion Starter #18
I figured out the shifter issue. It turns out it wasn't anything more than a simple oversight by me. And yes, I feel stupid. The clutch cover is the positive stop for the shifter shaft to keep it from sliding to the right. It has a circlip and washer that prevents it from sliding to the left. When you add the lock up clutch you need the spacer for the clutch cover to enable clearance for everything inside the cover. MTC also makes a spacer for the shifter shaft. It was in my box of parts but I forgot it when digging out the cover spacer. I'm sure I would've found it later but I just wasn't thinking about it last night. That's one of the problems with letting a project sit for long periods of time. I forget stuff.

Here's pictures without and with the spacer:





Everything's together and life is good. I was able to go ahead and finish the air shifter installation today as well:



 

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Discussion Starter #19
While doing the shifter I was reminded of something I did a long time ago and it illustrates that I'm a cheap [email protected][email protected]^d. I lowered the 12 for drag racing and when you do that you need lowering links; which I have on the bike:



and you need a shorter kickstand. Several companies sell them for at least $100 each.

Kawasaki - Ninja ZX10 - Frame & Protection - Schnitz Racing

I went to a salvage yard and bought an old ZX7 kickstand, cut it to length and my brother welded it together. We had to add a spring mount to the kickstand as well, so I bought a bolt that we ground down and welded to it as the return spring mount. I painted it before installing it but the paint has faded and chipped in the last 10 years...Total cost to do the mod? about $12. This includes the bolt, kickstand and paint. You can see the weld bead in the photo:



 

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Discussion Starter #20
I started today kind of slow. Somebody asked for details on my undertail so I measured it's dimensions, etc.. for him. I got it installed on the bike and now I need to start sorting the wiring. Here's pictures of the miniscule progress this morning:














The pictures aren't that great due to lighting. The inner fender follows the frame contour for a nice clean look underneath the tail.
 
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