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AV80R ZX-4RR build thread

113K views 880 replies 49 participants last post by  steiny  
#1 · (Edited)
I just picked up mine last Friday and have already fell in love after just 300 miles.

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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!

 
#272 ·
First track day was a lot of fun. Of course I loved the bike but the real treasure of the day was meeting @Chuck Graves, Shane @Gravesport, and the rest of the Graves gang (Tom, Jorge, Chris...)

Seriously the most welcoming and happy group of guys ever!

The van was packed up and it took me 5 1/2 hours in 100F heat to drive up to the track Friday afternoon

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I got there at 7:30pm and set up camp. It was so clear out at night.

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The next morning I was pretty nervous since it's been 6 years since my last track day and 23 years since I last rode this track.

I used some warmers for the first session mostly to make myself feel better, but they weren't really needed.

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I was very timid the first few sessions but I eventually started to get comfortable and trust the tires. The track is freshly repaved, and smooth as silk.

I remembered the advice from a friend about riding on the track: "Ride fast, take chances" So I started going for it a bit more after lunch. Had to be super smooth with the stock forks on corner entry since they have what feels like basically zero damping.

After lunch I was trying to follow Chuck's buddy, Tom, who was riding a tricked out N400. I just tried to let go of the brakes and get on the gas as early as possible to try and keep him in sight.

While flat out in 3rd gear in turn 7 behind him, the shifter scraped the ground and scared the heck out of me! When I was younger I would have been like "yeah! That's rad" at 46 I'm like, "thank goodness I didn't fall!" [emoji1787]

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So the bikes and track were great, but the people and community I met were even better.

Shane @Gravesport is the nicest guy! Was awesome to hear his interesting story of how he joined the Graves family and all the cool moto stuff he's accomplished.

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When you think your bike is really cool but then you park it at the Graves pit and realize you're not even close [emoji1787]

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I'm taking off my forks today and sending them to @Gravesport tomorrow. The Bitubo suspension is the way.

Everyone who rode @Chuck Graves personal bike came back into the pits with a wide eyed ear to ear grin.

I know mine won't be 340 lbs like his, but that suspension is a bargain. I consider it a "safety item" and my wife agreed.

She said "pretend you crashed just one time because your suspension sucked and buy it without crashing".

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Chucks bike [emoji7]

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Mine, with the last time you'll see the stock suspension on it!

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#763 ·
It was a great day. Finally got to meet @vcyclenut in person and we spent the whole day riding together. The smiles from a couple ZX-4RR's riding on track together was off the charts. It started sprinkling rain at the end of the day and I got to go out and enjoy an open track since no one was on. That was really fun and the Q5's did really well with a little moisture on the ground.

I have tons of videos and pics to sort through and then will have to post them up with a write up. I may just do a YouTube video instead since it's easier to talk through it than type it all out.
 
#829 ·
Disassembled for a deep cleaning and added PPF to the outer fork tubes and radiator tank.

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Also installed the CF parts I had laying around from my KRT.

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And the @Gravesport street riser clip ons with their aluminum throttle tube topped off with some Domino grips.

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#6 ·
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 😁

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

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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.

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A bunch of Graves goodies arrive later today so more when that shows up.
 
#46 · (Edited)
In preparation for my ECU to arrive back from @vcyclenut I need to remove the stock O2 sensor, plug the hole in the exhaust, and tidy up the connector on the harness.

Removed the stock sensor and bought a $12 one off Amazon to harvest the connector as a dummy plug.

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Remove the wires and pins off the Amazon O2 sensor.

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My favorite silicone is 1211, so use that to plug the rubber holes where the wires were.

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Harvest the silicone heat resistant sheath and toss the rest in the trash.

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Put the dummy plug all back together

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Look ma! No pins!

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Then grab some 1 1/4" 3:1 heat shrink without adhesive.

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Install the dummy plug

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And add heat shrink...done!

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Next I have this titanium M12 plug with washer

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Add my favorite anti seize for exhaust stuff (2000F)

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And torque to 18 ft lbs per the book.

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Now I just wait for my ECU to arrive.
 
#816 ·
In preparation for my ECU to arrive back from @vcyclenut I need to remove the stock O2 sensor, plug the hole in the exhaust, and tidy up the connector on the harness.

Removed the stock sensor and bought a $12 one off Amazon to harvest the connector as a dummy plug.

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Remove the wires and pins off the Amazon O2 sensor.

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My favorite silicone is 1211, so use that to plug the rubber holes where the wires were.

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Harvest the silicone heat resistant sheath and toss the rest in the trash.

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Put the dummy plug all back together

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Look ma! No pins!

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Then grab some 1 1/4" 3:1 heat shrink without adhesive.

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Install the dummy plug

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And add heat shrink...done!

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Next I have this titanium M12 plug with washer

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Add my favorite anti seize for exhaust stuff (2000F)

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And torque to 18 ft lbs per the book.

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Now I just wait for my ECU to arrive.
It appears that loctite has been discontinued.
 
#492 ·
There's this strange wet stuff that's supposed to start falling from the sky later today here in SoCal, so I'm hunkering down with the latest batch of parts from @Gravesport.

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Of course I'll bore all of you with another video and pics showcasing my ability to assemble parts without screwing anything up. 🤣
 
#701 ·
If anyone wants to buy the Sumitomo connector that matches the O2 sensor to make a dust cover for the harness after removing the sensor from the bike, here it is:


And a link to a M12 x 1.25 titanium plug for the exhaust header too:

 
#764 ·
After riding @vcyclenut 's 4RR on the street with GP shift, I'm swapping my KRT over.

The FTEcu sensor makes it easy to swap. Just switch two wires and move the linkage and adjust for optimal geometry (as close to 90 degrees on each end as possible).

Before

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After

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#40 ·
Let's undress this thing and take a look.

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Made in Thailand. [emoji2371]

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Taking the tank off was super easy with the quick disconnect. Barely a drop of fuel spilled.

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Unplug a couple connectors and the ECU is out.

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Disconnected the air temp sensor plug and pulled the bib back to take the airbox lid off.

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What you'd expect for 763 miles. Very clean.

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This little guy had a bad day!

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Installed the DNA reusable/cleanable filter in place and buttoned it all up.

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Put the tank back on so it doesn't get dented or damaged.

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Also took the opportunity to swap out the stock 1.1 bar radiator cap for a 2.0 bar one from Graves.

The Kawasaki coolant is a really nice shade of green!

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Now time to mail off the ECU to @vcyclenut and wait for it to come back.

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#114 ·
More goodies arrived so let's get them fitted.

Moriwaki frame hole plugs to bling up the ugly holes

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Carbon trim for the seat surround on the tail
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Carbon side air ducts

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Carbon belly pan

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Stick on the thermal tape and insert the rubber plugs

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Fit up is perfection with the stock lowers

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Looks like it could hold a couple quarts

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Underside view

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I'm really digging the carbon look that has emerged

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Here are side views showing where things are at.

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More to come as stuff arrives
 
#147 ·
More goodies arrived so let's get them fitted.

Moriwaki frame hole plugs to bling up the ugly holes

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Carbon trim for the seat surround on the tail
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Carbon side air ducts

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Carbon belly pan

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Stick on the thermal tape and insert the rubber plugs

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Fit up is perfection with the stock lowers

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Looks like it could hold a couple quarts

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Underside view

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I'm really digging the carbon look that has emerged

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Here are side views showing where things are at.

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More to come as stuff arrives
Do you have the link for the belly pan by chance? I’m assuming it’s from WeBike but I find the site rather challenging to navigate.
 
#161 ·
No ABS is SOOOOO nice. The brakes feel like they came ALIVE.

The combination of rubber lines and the longer routing to the pump feels totally different than the new steel lines that are shorter.

The bike lifts the rear wheel at will at nearly any speed. I was comfortably able to modulate it on my ride today and the feel is great.

The pads may need to be replaced though. I think some aftermarket ones may be better.

The front discs turned a little blue after todays ride, so I might have over done it a bit. [emoji51]

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Dialed in some more rebound on the rear shock. It's almost max'd out. I'm 1/2 turn out of 4 available.

Tires are slowly wearing out. Just passed 2000 miles.

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Time to clean, floss, and lube the chain again [emoji16]

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#168 ·
No ABS is SOOOOO nice. The brakes feel like they came ALIVE.

The combination of rubber lines and the longer routing to the pump feels totally different than the new steel lines that are shorter.

The bike lifts the rear wheel at will at nearly any speed. I was comfortably able to modulate it on my ride today and the feel is great.

The pads may need to be replaced though. I think some aftermarket ones may be better.

The front discs turned a little blue after todays ride, so I might have over done it a bit. [emoji51]

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Dialed in some more rebound on the rear shock. It's almost max'd out. I'm 1/2 turn out of 4 available.

Tires are slowly wearing out. Just passed 2000 miles.

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Time to clean, floss, and lube the chain again [emoji16]

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Vesrah pads are always the first brake upgrade for me.
I like the -XX pads for street/track use. ZZ pads are good too.
The stock front rotors seem to wear abnormally fast on these bikes.
 
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#216 ·
Measure and drill the locating hole for the left control. Some blue tape on the bar and a sharpie on the nub to mark where to drill makes it easy.

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Chamfer and deburr

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Ready to go

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Do the same for the right controls

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After installing it all in place, check vertical clearance for the levers and also lock to lock to ensure it doesn't hit the tank.

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The Graves clip ons really tuck the bars into the stock bodywork at full lock. Nice placement.

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Here are come comparison shots. I tried to be as consistent as possible when taking pics.

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Just sitting on the bike, I already like the change. I'll go for a ride tomorrow and really see what I think.

If you also install the @Gravesport brake guard, be very aware of the room you allow for movement of the brake master cylinder. The lever comes very close to the guard (2mm) when you push the master all the way inboard.

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#239 ·
The link pipe for the stock muffler just arrived.

I'm sending it out to @vcyclenut so he can create a tune specific to the Graves header used with the stock muffler.

First class service! I don't know anyone else that lets you bug them for weird stuff like this...and David doesn't even hesitate, he always wants to help. [emoji1334]

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#277 ·
I overheard @Chuck Graves yesterday telling someone that these Bitubo suspension kits will probably sell out, and their suspension wizard, Chris, is in Van Nuys until this Friday before going back home to Georgia.

Of course that means I'm gonna get moving and yank these forks off tonight. I gotta box em up and ship them out tomorrow to @Gravesport so hopefully they'll land in his hands by Tuesday, giving him and Chris enough time to do all the black magic to gut the Kawasaki stuff and stuff it with the Bitubo goodies.

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I'm sure they will tell me how high to have the tubes in the triple, but measured the stock position for reference.

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I forgot these forks have a top out spring. Very evident when you're holding them off the bike.

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My journey of buying other peoples parts and bolting them together is not anything special, but I'm having fun with it.
 
#523 ·
Or not enough. 😉

A bunch of really cool stuff just arrived moments ago.

The machining and tool paths on the side engine cover protection is perfection! Like fine jewelry.

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My favorite part of these race fairings are the seat. It's just a beautiful and elegant solution to what is normally a very ugly part of other race fairings.

I'll be doing all the paint on these fairings myself, DIY. I don't know why they call it painting, it should be called sanding. 🤣

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And of course some other odds and ends that are needed are included below.

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