Just realised it's been well over a year since my last update, must be because I spent last summer enjoying riding my hybrid!
I did change a couple of things to finish her off, the dynojet kit fitted in my last post was quickly removed. She just would not idle and ran like a bag of poo. Turns out that the carbs had already been modified and I had blocked another air jet, when I realised this and put them back to how they were, she ran smooth again.
With the pod filters the fueling wasn't right, probably due to a lack of setup. So I thought I'd have a go at making an airbox fit. The 4JH airbox was never going to fit under the tank, so I tried the 3TJ airbox. I opened out the carb holes and used the 4JH rubbers, but the box was too high up and the tank would not fit. I opened up the holes into slots up the airbox, effectively moving the airbox down into the middle of the bike with the carbs poking up into the middle of the box rather than the bottom. This fitted well enough but left holes open to the elements, I covered these with Duct tape. Simple but effective. I have also removed the snorkel and the air filter, replacing both with a pair of tights! That should keep the big bits of crap and flies out of the carbs...
I'll try and take some pics of the airbox...
Next up was the exhaust. I was never happy with the solid pipe bend, it was just uglly and would compromise ground clearance. The flexible pipe was only ever a temporary fix (even though it went through the MOT!) as it was a bit of a bodge.
The 4JH donor came with standard headers and a very mashed race can, the 3TJ came with a Japanese race can (no markings
), I just needed some way to connect the two. Ebay came up with a Thundercat link pipe at a reasonable price, so the headers went on and with the judicious application of a blow torch and long bar, the link pipe connected up to the can. She sounds just as nice, if a bit louder, still passed this years MOT though!
Last but definately not least is the front end swap. I wanted to try putting on an RGV front end as I had the forks lying around and liked the idea of USD with 6-pot brakes! After puttingthe yokes into a spare frame, it was obvious that the lock stops would have tomove, as the FZR has the stop at the front of the headstock and the RGV has it at the back. Judicious use of the angry grinder saw the RGV lock stops on the floor, which just left some bits of steel needing welding onto the yoke. I also drilled and tapped the new bits, to allow some adjustment in case I got the placement wrong!
In went the yokes, followed by RGV forks and clip ons, GSXR4 front wheel, axle and spacers, TL1000R 6 pot calipers, ZX10R master cylinder and 4JH switchgear! Bit of a mix 'n match affair!
That was the bike finished, well as finished as a project ever is!
I then spent the summer just enjoying riding, including 2 months as my main transport due to engine issues with my car!!
First impression on the road was that the engine was lovely and smooth with bags of torque for pootling around town. Well there's loads of torque compared to an RGV250... I could now follow traffic and overtake without the flurry of gearchanges and addictive power band.
More later...
Alex.
