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AV80R ZX-4RR build thread

113K views 880 replies 49 participants last post by  steiny  
Looks like the GaleSpeed has more adjustability than the Brembo's.
Either are good for the money and a good upgrade.
Looks good. 👍
 
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I think a 2nd ZX-4RR is on the cards for me. One stock one for the street and one beast for the track.
Best of both worlds doing it that way.
So then you'll have the joy of the bike in two setups not having to sacrifice time by swapping bodywork etc.

The wallet may scream a bit but hey we're all used to that. 😂
 
If you need a driver for the second van I can help you with that. Right to my storage. 😂

Congrats man on the new steed. 🙏🏽🤙
 
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Nice detailed review of the Prime throttle assembly. 👍
On the @Gravesport switch assembly is there no way to utilize 3 of the buttons to your configuration and just not worry about the other 2?

Grvaes products are no joke and although they're priced higher than some the quality of the work and little details are worth the purchase. 🤙
 
I suppose Graves should make a switch set up designed for all street functions.
That would be nice.
I may have to break my pledge to stop spending if so. 🥺
 
@AV80R As an aircraft mechanic what is your take on good-ol' copper paste as anti-seize?
That's exactly what I use.
It's a copper based high temperature anti-seize used for exhaust bolts etc.

Works good as I'm constantly working with swapping my exhaust on the car and the anti-seize makes removing the bolts so much easier without worry of breaking. 👍
 
Good to know on the valve cover bolts needing a check while mine is still in the naked state.
I'll be checking those for torque spec along wThe other bolts while I'm at it.
Thanks for the heads up tip. 👍

Also am I the only one that tore out that rubber mat bib on the bike?
This is the only bike I've owned that has had this and it's a pain in the 🫏 to work around. 🤬 😂

Nice work on the bike and glad to know I'm not the only one that's so anal about having a clean bike. 🤙
 
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The rubber bib kept 95% of the gunk from spreading all over the engine after I rode in the snow/rain. It limited the accumulation of gunk to the front of the block and also the radiator fan & shroud.

if you only ride on nice days, I bet you'll be fine without that rubber bib in place.
Yeah I'm a fair weather rider and stay away from wet roads and rain.
I've been caught in a few rain storms when I had the KZ400 decades ago with no issues except for the rain feeling like bees stinging my chest. 😂
 
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Might be more crucial to check once you actually have some miles on your bike. :whistle:

:p
Yeah you're right but I've got the bike apart so might as well make sure all is torqued to spec. 👍
 
It actually will be helpful in general for those wanting to have an idea of how to install race fairings.

Even if the fairings are different the info and ideas passed on will help someone. 👍
 
Do you guys mostly wear gloves? I sometimes "want to" and then within minutes usually come to a situation where I need fine dexterity and the last thing I can use is an additional layer between the fingers and workpiece (valid for other areas in life too). In other words they tend to get into the way so quickly I almost never use them, except maybe for DOT4 or Oil changes.
I never wear gloves, kind of like condoms, as I need the full feel of what I'm doing. 😜😂
 
Are you going to be using the OEM clutch discs and plates or are you upgrading?
Also any other modifications to your clutch assembly while you're in there putting in the new Suter setup?

I was keeping quiet with my purchase of not one but 2 Suter clutches, one for the 4RR, and the other for the N400. 🤷🏼‍♂️😉

Since the 4RR has 1 mile on the motor I'm going to be using the OEM plates as they're still new.
I'm adding the Spears SPZX400r Gear Shift Arm Kit with Detent while I'm in the housing to make sure there's no issues with dropped gears etc and the reason I asked if you were doing the same.

You going to be doing a how to on this for the forums? 🤞
Id planned on it but won't be for another month as I just got back on the road again.

Looking forward to a review from you once you get it all sorted, tested, and track verified. 🙏🏽
 
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"The stack up thickness has to be within a certain spec for the clutch to work properly, so buying all new parts was in order."

Im guessing you're taking into consideration the wear you have on your factory clutch plates in buying all new then. 🤔

I'll be measuring the stack thickness on my OEM to see if they meet the requirement for the install as I doubt anyone has done this already.
If needed I'll get what's needed to make it work but in theory shouldn't have to with still new plates. 👍

Yeah I got mine from @Gravesport as well and should be delivered for the second time after delivery failure the first time with signature being required and nobody home.
UPS delivers when everyone is working and in school. 🤦🏻😏
 
Did you have as much fun installing the Domino grip on the throttle tube? 😂
I uses isopropyl alcohol to install and kept adding as necessary to force this tight fitting grip onto the tube.
I think I broke a sweat doing so. 😂
No need for safety wire on the throttle tube grip but I will be doing so on the clutch side to make sure there's no slippage.

Nice work on the steed btw. 🥰
 
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Yeah the Windex has the ammonia in it so it too can be used and when dry leaves no slippery residue.

It'll be awhile when I change grips again but I'll definitely try that next time.
I keep a bottle in my 18 wheeled daily driver. 😉😁
 
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His account is still here and open for use so he didn't get banned. 👍
When I left the forums they banned me for no good reason. 🤷🏼‍♂️

So either Arash got pissed about something here or about an admin and probably left.
I think we all miss him and he was one of the original OG posters here when this forum came to be.

Hope to hear from you soon Arash. 🙏🏽