Project ZX9

[Mattpack]

Seeing as i bought this bike from a fellow PSB'er and everytime i get a visitor i get asked "why isnt this build on PSB" i thought i would bring you up to speed with this bike.
My mate and i had a large work contract pushed back a couple of weeks so we decided to fighter my newly acquired 95 ZX9 (seeing as my gixxer fighter was sold). I had planned to do this build over xmas but......shit happens

Here it is the day i picked it up. 38k Ks on the clock and been garaged for some time.


Then when i was trying to make the mould for the tail, xsnoise turns up with a tail to donate off an 07 cbr1000. Perfect!


Then set about making the subframe. At this point i was pulling the back off and working on it then fitting the original back on so i could ride home


The under tail exhaust was next to nut out. Lot of research on making those mufflers.


Then on the 1st of this month, we decided to go flat out. Working late into the night nearly every night. Stripped the frame and welded up all un-necessary recesses and bolt holes for polishing


Let the polishing begin......


Then re-assemble everything. The engine was in great condition, compression etc. Fixed a minor clutch problem while the engine was out and gave it a chemical treatment to remove all white scaling.


The rims were stripped, all casting marks removed and smoothed out. Outer sections polished


Then the first look in colour


I got the rims back from having tires fitted yesterday and have the pro-tapers on


And tonight was rear lights and number plate holder. (mostly trying to get the wiring run through the bracket tubes from the indicators.)

[Jacko]

Looking good so far.

[fatoxious]

sweet man, can't wait to see it finished.

[Cam]

Woah. Moar.

[Mattpack]

If people want to see any particular parts of the build just let me know and will post up more detailed pics.
So, today was day 18, we fired it up for the first time and it sound great. Couldnt be happier. Will need re-jetting for the new intakes and exhaust but all in all it ran really well.
The headlight will be here tomorrow, and the dash on Monday (doing the ebay wait aaahhh). Will do a full list of all the parts that have gone onto it at the end. Im really keen to ride it on the weekend to see what the exhaust has done to the power range. My money is on good top end, boggy bottom end. Re-jet and carby balance should trim that a little.
Man am i looking foreward to having a life again. A night on the couch...........bliss.

[Mattpack]

Oh, and Lunar-c, thats not the same red we put on your bike. lol. Yours is a much nicer red but cant do 2 bikes in the same colour. Will take a pic in the sun tomorrow and you will see the difference. You should be able to take it for a spin when you're down next week.

[GenocidE]

Even God shines upon this bike.



Cant wait to see it finished and would love a video of the exhaust sound.

[chief wiggum]

have fond memories of my B2, same colour scheme and all. thought about fightering it at one stage, but sold it instead. looking good

[Goofy]

That exhaust is awesome. Any more pics on how you did it?

Nice work on the subframe too.

[BlackFZR]

Great work on the custom exhaust. For a 900cc, it seems to be very small diameter though.

[Angel09]

Keen to see the finished product, have a soft spot fot the ZX9s.

[resist]

I like, I'm no great far or risers though, I wish fighters weren't so quick to ditch the clip ons.

[Commander Keen]

Instant hardon subscribe.

[Mattpack]

Great work on the custom exhaust. For a 900cc, it seems to be very small diameter though.

Yeah we had the same thoughts but crunching the numbers on volume and pressures it works out it should be a little smaller. They are actually bigger than what it looks in the picture. With no restrictors in the whole system, back pressure had to be found somewhere. The test ride on the weeekend will be the deciding factor.
I do have to find time to dig through old threads on this topic. Im sure ive seen formulas posted up before. All advice and suggestions are greatly appreciated.
As for the keeping the clip ons, i come from a motocross back ground, and the day i sat on a fighter with an up right position, i felt at home. Great for wheelies too. Dont get me wrong, i love my SP-2. Horses for courses i suppose.

[Mattpack]

Another late night but good progress. Headlight arrived and on, made new tank mounts and lots of small jobs. Getting closer.....

[BigTim]

Must've missed this when you first posted it.
That's looking sweet

[GenocidE]

Stick some fuel in and start her up on camera I'm itching to hear it.

[Dubs]

Must've missed this when you first posted it.
That's looking sweet

Same

Congrats on the build and almost finished product Matt, great job.

Thread need vids soon tho

Dubs

[lunar_c]

You copied my bikes colour..!

[Aceshigh]

You copied my bikes colour..!

Nah he didn't.....

Oh, and Lunar-c, thats not the same red we put on your bike. lol. Yours is a much nicer red but cant do 2 bikes in the same colour. Will take a pic in the sun tomorrow and you will see the difference. You should be able to take it for a spin when you're down next week.