2011 ZX10R Race bike build, from street to track.

[TurboR1]

After half of 2010 racing a 2003 Yamaha R1, the race bug had bitten and had bitten hard.

I wanted something new(er) to continue racing and after seeing the pictures and specifications of the upcoming ZX10R it gave me an economically viable alternative to BMW's S1000RR which I was also looking at. After seeing one in the flesh in road trim it looked (like most Kawasaki's) less than a supermodel, but after taking one for a spin through the suburbs I was sold...

So come January 2011 here I was with the ZX10R loaded up in the van ready to take home on Saturday morning... Didn't even bother registering it, though Maya got to ride it first... from the shop front to the van.



Get it home and take a photo before work begins.

Ugh those mirrors...


Ugh that exhaust...


New? Really new...


Into the garage and by Saturday night everything that isn't need on a race bike gets ripped off.

Gone are the mirrors, indicators, snow shovel fender.




Now with these things being so new one major problem occurred... No one has made any race kit parts yet.

[SOLID]

Without the mirrors its got a little of the RSV4 look to it (puts on flame suit)

[Cbr Junkie]

So are you gona run it in all gentle like?

[TurboR1]

Scouring the internet for hours (and hours) small bits and bobs are found... and the first thing, despite being probably the most boring thing is also one of the most important parts available, radiator guard.



I gave my screen to Ralph to do the front number board, BlackFZR provided the "Turbo"



With race fairings still to be ordered, all I can do is tape up the headlights and get some track time in effectively a stock bike... Adding some pin stripes to the tank side panels I'm building up the theme for this bike.



Airbox cover with some more graphics added...



The only other thing available at this early stage was generic parts such as cross drilled caliper bolts and other little fittings that allow them to be lock-wired in place.

[TurboR1]

Mid to late February and things start to pick up momentum;

The race fairings turn up form the UK, manufactured by the MSS Kawasaki BSB team, they are sent straight to PSB's Potato for a fresh coat of paint...

Best James Earl Jones voice "Luke... I am your father"

[TurboR1]

Superbiketoystore.com was able to supply an Akrapovic link pipe which gets rid off the valve in the exhaust, the catalytic converter and about 40kg,



Also a new tank cap;


After another Probolt order I get all the Dzus fasteners and hardware I manage to get the fairings fitted up



While waiting for more parts to arrive I'm left with little else to do other than add a fer more graphics;

Tail;

[jules_1972]

Awesome!!

Keep it all up and running with new pics dude!!

And a dyno chart!!!!

[SOLID]

[TurboR1]

Ralph at Causeways come though with a tidy haul of gear just before the HCMC night meet.

Vortex sprockets to change the gearing, GoodRidge braided lines, shark guard from ZAP, Genuine Kawasaki engine case protectors.


To work and the engine case covers are a doddle to bolt on and are done in a matter of minutes, drop the coolant out and replace with water, (to a Ducati owner this sight would be normal on any other day)




Since it's a night racing meet on goes a red light at the back;


Also added is a set of "Jet Intake" graphics further adding to the theme of the bike.


The HCMC night meet comes along and another little lull until my next order comes in the mail.

I didn't change out the brake lines at this point as the all the ABS plumbing (what feels like a kilometer of tubing) looks like I might bite off more than I can chew so close to a race meet.

Shorty after though it's all ripped off with the braided lines in place. bye bye ABS thank god!

[NMBRPL8]

When you rip off the stock muffler, sell it to meeeee! haha lookin the goods anyway, will be interesting to see your results, there have been some very good ones so far.

Edit: You might find that pulling out the ABS bits will just throw constant codes, possibly not even let the bike run. There are a limited number of non ABS ninjas for track use, trying to recall the seminar now but i think the gist of it was that you cant fully remove the ABS. The pump on it is freakin miniscule anyway, and so light! Other race bikes have left the abs as is.
Other note is if you want you can drop the battery from i think its a 7 to a 5, will save a bit of weight off it there, just top up the charge prior to a meet.
Final note is the back torque limiter will be set up somewhere in the middle of the range out of the box, can shim it up to the max for the track, but if you have the workshop manual im telling you stuff you already know.

Lookin sweet like the graphics theme

[TurboR1]

Nothing much happens as a overseas work trip cuts into preparation time and all that gets put on is some more graphics;

Revised tail;


Nose;


Front guard;


Tail again;


Side graphic;


Zoom out belly pan graphics on;


And the other side still running the stock muffler at least I've got some slicks on it;


Hang on... haven't we seen something like this before??? An earlier pic before the belly pan graphics went on and before I put slicks on it.


Some theme music to suit while I type up the next few installments;

[Seb]

Very nice Turbo, looking forward to watch this build progress.

[NMBRPL8]

Its times like this i wish there was a *like* button similar to facebook or a thumbs up like youtube. The side by side shot looks awesome, now get the same shot fighting for position on the racetrack

[TurboR1]

Back from a long work trip more parts have arrived... things are getting quite full on.

As stated by NMBRPL8, removing the ABS module does indeed give you an error code, it will also not let the bike rev over 11000RPM, with the servo motor removed. But after having removed the exhaust servo I had an error message anyway. Leaving the ABS servo motor plugged cured the 11000RPM problem though.

But first yet another change to the tail;


Wanting to reduce crash damage costs I decided to get some Woodcraft Clip ons (a $16 replacement bar vs a $300 OEM item in the case of a tumble) these are really a must; Superbiketoystore again.


I wanted more power from my brakes, the standard Kawasaki set up was always going to be a weak point... what else other than a Brembo master cylinder??? complete with fold up lever option.


A clutch perch with a fold up lever was also on the shopping list, and for no other reason than to bling it to the extreme I went for this uber trick CRG item;


Both items fitted and ready to roll,
The Brembo gives amazing initial bite, kind of like someone sticking a metal rod in the spokes of the front wheel, just the way i like it;


The Clutch perch is just as functional as it is sexy to look at, it lets you adjust the clutch cable tension on the fly courtesy of a little ratchet tab that pulls in 1/4 turn with each flick of your thumb;

[NMBRPL8]

You seem right on top of it, but you can get a little device to fool the exhaust servo actuator, check out Welcome to Skutr Net - superbike toystore might have a supplier for them or a similar item? Servo doesnt weigh much but its a race bike right A servo buddy should cure your error message.

There should be a disclaimer in the title if your going to include bike porn this hot clutch lever is art.

EDIT: reread and noticed this is all a long post of current progress from january, so here i am being a dick and offering advice lol. My bad, frikken awesome job on the bike, will keep my yapper shut now and watch the progress unfold. Still loving that clutch perch setup.

[TurboR1]

At the same time as the arrival of the hand controls Ralph came through with this;



This unassuming bunch of wires and black box is now the brain and nervous system of my race bike, Kawasaki factory racing ECU and Kawasaki factory racing harness.

This gets rid of all the ABS rubbish, no longer is there any ABS electronics or mechanics on this bike. (Ryven would hate it). What it does give you is fully programmable control over all 3 engine maps right trough out the rev range, 30 selectable traction settings, programmable engine braking maps for off throttle engine braking. Insane.

It also has a pit lane speed limiter switched on and off via the indicator switch. Also adjustable to any speed you choose. (40kph for barbs)

All the previous error codes caused are cleared and I can spend my time getting lost in the software.

What is doesn't give you though is electrics to run the fan (since factory race bikes don't have them due to their deep core radiators) I cobbled together a small toggle switch;
Awesome dash is awesome.

[Nickerz]

Awesome. Just frikkin ORSUM Rob.

Now win. Much

[TurboR1]

Next up, Rearsets... again these took a very long time to come on the market. But Ralph came through with the goods again;

Super grippy pegs, almost too grippy as they took some getting used to.
Lightech make a quality item.


Before and after LHS;




RHS;

[TurboR1]

The really sad thing was at this point I was still running a stock muffler.

Having borrowed one for the State road racing championships I had to get one for myself. However with the recent purchases I was more concerned having enough cash left for food and had to pause and save up again the credit card hemorrhaging to a point where I was certain that I would lose my house, my wife and some hair.

Once in the clear again (well a slightly paler shade of red), I sent away for this little beauty, Arrow works slip on and link pipe;


And on the bike;


Another angle, also with a cheapy exhaust bracket which gets rid of the foot peg mount, this is between State round 1 and 2. Slightly revised belly pan graphics.

[Bowlen]

That bike looks fricken mint!
I would hate to think how much its all costing