My ZX12R Winter 2019 Project - Kawasaki Forum :: KawasakiWorld.com
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post #1 of 21 Old 10-16-2019, 08:16 AM Thread Starter
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My ZX12R Winter 2019 Project

The "insanity" level just keep on rising... It just has to be true love to pour this much money and time into an old bike... -But love is love ... any way.......

The OEM fairings have started to look kinda sad and become brittle with age. So searched Ebay and found a cool looking "China" fairing set. Did not have high hopes, but then again, you get what you pay for, and I did not spend a whole lot on this fairing kit, so... I was how ever surprised when I opened the box. The paintwork is really nice on these fairings. Sadly there was one small nick on the tank cover , probably not the fault of the China company who made the fairings, culprit is more likely to be found among the personell who work within shipping...

The paint job was the nice part.. Then came time to start to fit the fairings to the bike. Again with everything aftermarket seldom does things fit, as was/is the case with these fairings. Many hours of mount the fairings on one at a time, then taking the fairing off to do some modifications to get it to fit somewhat good. Just so you know how bad the fitment can be with these aftermarket fairings. I spent about 4 hours just on the tail fairing to get it to fit somewhat acceptable and curse at the pillion cover because it does not fit that great.. (I am very OCD so...) The front fairing with the head lights and stuff was actually not that bad and the tank cover also fit nicely. The cover fairings that go over the air intakes and hides them did NOT fit for "poop". Gonna reuse the OEM ones and just sand them down and paint them satin black... Then the bastard side fairings.. I just have the right side done, still need to fit the left and then mount the fairing pieces that go inside the side fairings (that will probably be lots of fun)...

any way... At this moment the project is only at the stage of fitting fairings on one by one in the best way possible, so it won't look like "poop" once done. I still have to add heat shielding, decals, etc... But I think the end result will end up looking good. I'm not using just "OEM" decals, I going with more a personal and custom touch on the detailing...

I also ordered a bunch of other stuff to for the bike... I will keep updating this thread as the project rolls on....

/Tom
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File Type: jpg IMG_20191015_235305.jpg (2.30 MB, 28 views)
File Type: jpg IMG_20191015_235335.jpg (2.26 MB, 27 views)
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Last edited by Mefirst; 10-16-2019 at 01:58 PM.
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post #2 of 21 Old 10-16-2019, 01:55 PM Thread Starter
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Update...

Fairings are fitted as good as possible. Took allot of time and patience, but I am quite happy with how it turned out. I am still waiting for the postman to deliver the decals and some other stuff, so can't do much more right now... other than enjoy a cold beer for a job done great....

I do have a plan and "picture" in my head how my bike will look once it's all done, but I'm not gonna tell you, you'll just have to come back and check this thread if you wan't to know I will do some service at the same time I take the bike apart...

/Tom
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File Type: jpg IMG_20191016_210507.jpg (1.65 MB, 27 views)
File Type: jpg IMG_20191016_210559.jpg (1.86 MB, 29 views)
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post #3 of 21 Old 10-16-2019, 02:14 PM
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Fairings look good. Oem stuff in good condition is getting hard to find. Expensive too.
Who was the vendor for these fairings?

cmg
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post #4 of 21 Old 10-17-2019, 11:14 AM Thread Starter
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Quote:
Originally Posted by color me gone View Post
Fairings look good. Oem stuff in good condition is getting hard to find. Expensive too.
Who was the vendor for these fairings?
cmg
Thanks! I do like to look of the fairings, and I think they will look really cool once I've added decals.. Here in Sweden it is impossible to find OEM fairings. Also the issue is that with age the plastic will become more brittle. I thought for a short moment if I should just paint the OEM fairings, but decided not to because they are so brittle and will only end up cracking. A have fixed (plastic welded) a couple of cracks in them already... Also the prep and paintwork of the OEM fairings would end up about same in cost....

I bought the fairings through Ebay from a "company" named "Sport Fairings". I actually believe all these "China" fairings out on the market are made by the same company and then just sold using different Ebay "dealers".

/Tom
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post #5 of 21 Old 10-22-2019, 05:16 PM Thread Starter
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Update..

Spent a couple of hours in the garage. On the "to do" list was to change the seat covers. I have never done upholstery work, but first time for everything. I did how ever check out two videos over at YouTube about changing seat covers, before I had a go at it. It is not hard but you do need strong fingers, be very methodical and have a good quality staple gun. Also a heat gun is very good to use on the material to heat it up a little before and help stretch it. A little heating will result in that the material is easier to work with, wrinkles in the material is easier to get rid of, which in the end will result in a really good fit and looking good...

I am happy with how the change of covers turned out, not ever having done work like this.. I bought the covers through Ebay. It's a guy in Poland who makes them, quality is outstandingly good..

Added a couple of pictures, did not take many pics, but you'll get the idea and how it turned out. I am

/Tom
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File Type: jpg IMG_20191022_215651.jpg (1.71 MB, 21 views)
File Type: jpg IMG_20191022_223302.jpg (2.24 MB, 21 views)
File Type: jpg IMG_20191022_214024.jpg (1.93 MB, 21 views)
File Type: jpg IMG_20191022_230609.jpg (2.22 MB, 21 views)
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post #6 of 21 Old 10-23-2019, 04:43 AM
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Looks professional ! You made the new seat cover?

cmg
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post #7 of 21 Old 10-23-2019, 05:15 AM Thread Starter
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Originally Posted by color me gone View Post
Looks professional ! You made the new seat cover?

cmg
Thanks! First time doing upholstery, probably a bit of first timers luck to, that it turned out so nice.. I did not make the covers, I have no sewing skills what so ever, then again, maybe I should give that a try to... any way, bought the covers from Ebay.

This is the guy's Ebay shop who made the covers... https://www.ebay.com/str/firmawijalis The covers are made with high quality materials and you can also order/have him make custom ones (Lot's of different material/colors to choose from)

/Tom

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post #8 of 21 Old 10-23-2019, 05:56 AM Thread Starter
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Also, forgot to add these pics yesterday when I was updating my project thread...

I could not resist attaching the decals to the bike after I had finished the work with the seat covers... All decals/emblems bought through Ebay.

Found these 70-80's tank cover "Kawasaki" emblems (China). The emblems were a bit of a pain in the butt to fit/attach, because they are "metal", need to bend them slightly to get them to fit against the tank.. Then again they do look so much cooler than the OEM emblems.

Bought a set of fairing decals from this seller on Ebay (Bulgaria) https://www.ebay.com/usr/335dani?_tr...53.m2749.l2754 The decals are high quality vinyl. I only used the side fairing "ZX12R" decals from this kit.
Only thing is, when I put the left side decal on it got a small wrinkle in it, I managed to smooth it out, but I can still see it, again my "OCD", a little farther away you can't se it.. but still.. also when attaching the right side decal I did not manage to attache it perfectly centered, it's just some 1-2mm to far to the rear, but still...

Then last, raised "Ninja" decals on the sides of the rear fairing. (Also from China)

/Tom
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File Type: jpg IMG_20191023_000648.jpg (2.27 MB, 32 views)

Last edited by Mefirst; 10-23-2019 at 06:06 AM.
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post #9 of 21 Old 10-28-2019, 12:53 PM
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Looks killer! Now just get rid of that red stripe on the front rim!
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post #10 of 21 Old 10-28-2019, 02:39 PM Thread Starter
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Looks killer! Now just get rid of that red stripe on the front rim!
I will I just havenīt got that far into the build yet...

Iīve probably lost my mind but Iīm really thinking seriously about buying a set of O.Z Piega wheels for the bike. Reason is, I sold another bike I had, a 1998 Yahama V-Max, that money sponsored everything I have bought for my ZX12 so far... and I still got some money left over from that deal.. so kinda think itīs ok to spend the money on the O.Z wheels...

The postman has been leaving packages for me all last week and got the last two today.. so I now have all parts I need to compleat the build... I will how ever decide about the wheels at a later time, because there is the option to just beadblast the stock wheels and paint them the colour I want... buuuut... the OZ wheels would be so cool though... and if I ever decide to sell the 12 I can always sell the OZ wheels on the side...

I will update the thread later this week...

/Tom
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post #11 of 21 Old 10-30-2019, 06:02 AM Thread Starter
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Update...

Spent an evening in garage test fitting new parts to the bike.

Bought a Woodstock exhaust bracket (Pillion footrest delete) from Webike (Japan). Perfect fit. -Yes this bracket is more expensive than the typical stamped ones like R&D, BUT the Woodstock bracket looks so much better..

Took off the OEM rearsets and bolted on a rearsets from Gilles Tooling (Ebay). Sadly Gilles do not sell the Gold anodised sets that I really wanted anymore (according to the Ebay seller/shop from Germany, I did also check Gilles webpage and seems to be true. How ever seller gave a me a discount on the rearsets because the set I originally bought was the gold adonised ones but he could only deliver the black ones. That was nice of him..). Then again the Black set does look good to.. but the rearsets not being gold color kinda screwed with the final look I want for the bike...

Side note... There are several ways to adjust the Gilles rearsets. Problem is the tie rod that comes with the set is to short to use for some of the settings. At the more "extreme" settings the tie rod does not thread deep enough into the foot/lever assembly threaded rods. Well it does, but then the gear lever is in and uncomfortable position, IF using Race Shift then it would be ok.. They should have put a shorter and a longer tie rod in the kit or maybe a longer rod is missing from the kit I got. Going to check with the seller if that is the case... For the moment I set the footrest in slightly higher position (knees more bent) than the stock ones. I will have to experiment more once I am able to ride the bike again (winter intermission over here).

Also bought a set of chain adjusters (Ebay, from China). These adjusters are actually made for a ZX10. The adjusters fit with out any issues. BUT using the paddock stand pins attached to the adjusters is probably not a good idea. When doing work on the bike I will use the paddock stand pins attached to the swingarm (OEM position) and just unbolt the pins when not doing work/service on the bike, takes only seconds to do. The new adjusters are more for the look. The adjuster bolt "clicks" when you turn it to adjust the chain tension, I really like that.

I still have some parts to test fit, an update will come. After I know everything fit like it is supposed to, I will take the bike apart for a through out cleaning and service.

On the "to do" list is new bearings to the swingarm and suspension pivot linkage. When I did the shock change to a Wilbers in the early spring, I did check all these bearings and greased them but because I will paint the swingarm black, I will put in new bearings at the same time. I will also paint the lower forks black because the aluminium is pitted and looks awful. Do some other minor paint touch up here and there on the bike. I also have to deal with, as many of you have, with a minor oil leak from the valve cover, I'll also change the spark plugs at the same time.

/Tom
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File Type: jpg IMG_20191030_013101.jpg (2.08 MB, 20 views)
File Type: jpg IMG_20191030_013010.jpg (1.79 MB, 22 views)
File Type: jpg IMG_20191030_013041.jpg (2.13 MB, 19 views)
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Last edited by Mefirst; 10-30-2019 at 06:24 AM.
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post #12 of 21 Old 10-30-2019, 06:50 PM Thread Starter
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another update...

Again had some time to spend in the garage and got some things done... The job for the evening was to test mount the Brembo RCS19 master cylinder, Rizoma brake fluid reservoir and a Brembo clutch lever... Looks good

Still left to do is wire the brake light switch, cut and fit a hose between mc and reservoir and finally, fill and bleed the brake system...

/Tom
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File Type: jpg IMG_20191031_012644.jpg (2.22 MB, 16 views)
File Type: jpg IMG_20191031_012718.jpg (2.33 MB, 17 views)
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post #13 of 21 Old 10-30-2019, 07:09 PM Thread Starter
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also while I was at it... Added two more decals, well one to be exact.. but both are a "shout out" to two of my heroes... Valentino "WLF" Rossi #69 and Guy Martin #8...

The 8 ball decal also covers the small nick the tank cover got during shipping...

/Tom
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post #14 of 21 Old 10-31-2019, 03:22 PM
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You have some very nice kit on this hot rod of yours. Very nice.

cmg
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post #15 of 21 Old 11-01-2019, 07:38 AM Thread Starter
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You have some very nice kit on this hot rod of yours. Very nice.
cmg
-Thanks!!!

/Tom
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