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AV80R ZX-4RR build thread

1090 Views 37 Replies 8 Participants Last post by  Swamp Daddy
I just picked up mine last Friday and have already fell in love after just 300 miles.

Tire Wheel Fuel tank Vehicle Plant


I'm the president of the ZRXOA and have spent tons of time and money making my ZRX1200 more powerful and way lighter. Now I'm ready to go bonkers on the ZX-4RR and do the same thing.

I called Graves today and I'm on the list for their full titanium exhaust system that is being welded up now. It should be shipping in 1-2 weeks. I opted for the high mount version since that will have more mid range than the shorty version.

As soon as I get the exhaust, I'll be shipping them my ECU to get their flash and uncork this thing.

Shipping today from Graves:
Aluminum throttle tube
High flow air filter
Aluminum gas cap
Front & rear wheel captive spacer kit
Tank grip
Axle tool
Smog block off plates
Aluminum engine mount spacer kit
Swingarm spools
Works 2.0 Bar radiator cap
Aluminum valve stems

I plan on replacing every fastener I can with titanium or aluminum, as well as titanium axles and swingarm pivot. The wheels will be changed and the ABS pump will be deleted.

I'm really interested in the details on Graves 341 lb spec bike. I will gladly turn to them to get this bike on a diet!

For now, I'm just going to keep piling on the miles until that full exhaust gets here. It's been fun putting around in 6th gear but I can't wait to spin this bad boy up to 16k!

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What wheels are you going with?
I'm curious to know as there's so few wheel companies that have the r&d for anything 4RR related.
Thanks
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ya me too :rolleyes: maybe this guy know something i don't hehe @misnblu ( don't worry we'll be the 1st to have wheels on our bikes) 馃槑
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Off the shelf there may not be much available yet, but with a lathe and some patience, you can make spacers to fit up wheels from other existing applications that are appropriate for the ZX-4RR.

I saw those nice Taiwanese wheels that are available now for the ZX-4RR fitment out of the box, but I think I'll be going a different direction.
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In the first 400 miles for break in, I progressively increased RPM until I was doing full throttle runs in 6th up to 134 MPH right before the oil change.

0-100 miles I kept it below 7k
100-200 miles I kept it below 9k but spend most of my time at 7-8k
200-300 miles I kept it below 11k, and spent a lot of time between 9-10k
300-400 miles I hit redline in the first 3 gears and did many WFO 6th gear runs to 120-134 mph

All of the above was always varying rpm and engine load, never cruising at a constant rpm or throttle.

First oil change exactly at 400 miles which seems apropos 馃榿

Vehicle Motor vehicle Automotive design Motorcycle Font


Took me a minute to figure out how to remove the left fairing but eventually got it off and started draining the oil.
Liquid Fluid Ingredient Gas Food

Dishware Ingredient Cuisine Dish Fluid


The oil filter I was given by my dealer (16097-0008) is different than what I took off the bike (16097-0552) but it looks like it's just superseded from a Thailand manufactured one to a China made one.

Table Drinkware Yellow Kitchen appliance Drink


I hammered on this thing pretty hard from the 300 to 400 mile mark, so I'm going with Redline 10W-40 for this oil fill.

Bottle Liquid Drink Alcoholic beverage Automotive tire


A bunch of Graves goodies arrive later today so more when that shows up.
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Do you have to remove the faring to change the oil ????
Do you have to remove the faring to change the oil ????
Not mandatory, but I wanted to check things out since it's new. There's enough room to remove the filter and drain bolt, and have the oil drain right into the pan without ever removing a single panel.
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With the filter change, 3 quarts of oil brought it right to the top level line in the oil window.
Hood Motor vehicle Automotive tire Bumper Automotive lighting


The first batch of parts from Graves has arrived

Rectangle Composite material Automotive lighting Fashion accessory Auto part

Material property Electric blue Font Auto part Plastic

Material property Electric blue Font Plastic Publication
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Did a short walk around and start up video after the oil change for some buddies that are interested in buying one of these.

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Ok, stock weight off the showroom floor with a full tank of gas and oil filled to the top of the sight window is 420.2 lbs.

Kawasaki claims 414.5 lbs curb weight with a full tank of gas, so maybe they're filling the oil to the lower level. 馃し馃徎鈥嶁檪锔

Do the California bikes have any extra emissions?




Oil at the upper level mark



Fuel topped off



Key in ignition and plastic cap for the steering stem stuck back on.



Tool kit under passenger seat included



Removed QuadLock phone mount



Included rear reflectors with bracket and mounting hardware



Front reflectors and passenger strap included.

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For comparison my street legal Aprilia RS250 weighs in at 331.4 lbs with a full tank of gas and the oil injection tank halfway filled.


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First up today is the Graves throttle tube. The stock Kawasaki one allows you to roll off about 1/8" into "negative travel", which just feels weird and terrible.

The bar ends came off super easy and the switchgear unscrews with 4 bolts to get the throttle tube off.

A blast of air removed the grip off the stock tube and it was a simple affair of installing the grip on the Graves tube and putting everything back together.

Feels much nicer with no "negative travel".







Also slapped on the Graves swingarm spools. Ordered titanium bolts to replace the steel ones that are in there for now.

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Installed the Graves tank grip pads.

Perfect balance of function while remaining almost invisible.

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Silly question, but what is the swing arm spool bolt size? Never really looked, as I just used the ones Graves supplied.

And as far as I know, US/Canada (inc. California) all have the same emissions stuff.
Silly question, but what is the swing arm spool bolt size? Never really looked, as I just used the ones Graves supplied.
It's M8 x 1.25 25mm

I bought these titanium tapered socket head bolts.

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First up today is the Graves throttle tube. The stock Kawasaki one allows you to roll off about 1/8" into "negative travel", which just feels weird and terrible.

The bar ends came off super easy and the switchgear unscrews with 4 bolts to get the throttle tube off.

A blast of air removed the grip off the stock tube and it was a simple affair of installing the grip on the Graves tube and putting everything back together.

Feels much nicer with no "negative travel".







Also slapped on the Graves swingarm spools. Ordered titanium bolts to replace the steel ones that are in there for now.

What difference do you feel from 0-10% throttle cranked over in a corner vs the stock throttle tube?
This is one of my very few complaints with the stock bike.
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What difference do you feel from 0-10% throttle cranked over in a corner vs the stock throttle tube?
This is one of my very few complaints with the stock bike.
It functions exactly the same as stock except the negative travel is eliminated.
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Made a pattern for a headlight protective film cover using CAD. Crayola Aided Design





I use a drop of dish soap in some water and a small squeegee to install these bubble free.



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Nelson Riggs CL-1060-R Commuter Lite tail bag fits great.









Expands a little which is nice




Installs without rubbing on any shiny bodywork which is mandatory

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