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AV80R ZX-4RR build thread

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114K 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!

 
#799 ·
Another track day coming up this Sunday for the Graves KRT.

Even though it only did 130 miles at the last one it's prudent to disassemble, clean, and inspect before the next outing.

The race fairings from @Gravesport make this so nice. It took me only 4 minutes to go from ready to ride to totally undressed.

Here are all the fasteners needing removal for the fairings, fenders, and tank.

Fairings - 6
Front fender - 4
Tank - 4
Rear fender - 3

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#805 ·
#809 ·
I was waiting for that and was betting it would be the first comment.

I'm an FAA inspector and technician so quite familiar with the right and wrong way to apply safety wire to aircraft.

Spring clips are not safety wire, nor can they ever be installed to perform the same function.

In this non-aviation application, the clips can only be inserted in one orientation. Also you can't have any tension on the wire because then the clip wouldn't be removable.

The only purpose of the safety wire is just to keep the clips hanging off the caliper after removal so they can be reinserted quickly, without losing them.

Safety wire done correctly prevents the fastener from coming loose. In this case, the goal is different.

In a worst case scenario where the fastener comes loose, I want the bolt to turn no more than 1/4 and stay with the bike...which meets my needs for a vehicle that never leaves the ground.

Ease of serviceability during tire changes takes priority.

Technically, no safety wire or any other retention system is even needed on those caliper bolts.


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#814 ·
Is it safe to assume that the Suter clutch is better suited for track bikes, but street bikes like Swampy would be fine with the spring upgrade?
Yes, you are totally correct. The Suter is very track focused. I was doing some wild stuff with it today...intentionally downshifting into 2nd way too soon while braking hard and using the rear brake the back into the first corner at the end of the front straight.

That kind of nonsense is definitely not for the street!

I give up. I see that your KRT has an aftermarket rear sprocket, but I can’t find the post with its info in it. So either you didn’t post about it or more likely I missed it. What brand is it? Did you change the size?
It was made by CeraCarbon and is 48T (stock).

Took me a long time to get them to make it and ship out to the USA. They don't have an online shop.

It's ridiculously expensive but this is the sprocket used by many moto2 and motoGP teams, and was a fun novelty item to get on my bike.

Unfortunately, I need to change gearing so it may come off for a bit as I experiment.

Even though I'm interested in trying a different sprocket, this one will stay with me either on the 40th or KRT.
 
#815 ·
The Graves KRT is so dialed in. I made a couple tweaks to tire pressure and a small change to the fork compression and the bike is so easy to ride.

I'm sure some of this has to do with riding in a more flowing way, but the tire wear on the Q5 is outstanding.

The front has one day on it and the rear has two.

Front left

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Front Right

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Rear Left

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Rear Right

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#823 ·
#826 ·
The front tire on my 40th was giving me the heebee jeebees in the canyons yesterday, especially when it was cold and first starting out.

After 1800 miles the front is way more worn than the rear. I've been riding this one a lot differently in the canyons than my KRT. A lot more of a flowing style barreling into turns maintaining momentum with little braking and acceleration.

I think it's time to replace the GPR-300's with a set of Dunlop Q5...and my next thought is maybe this one needs the @Gravesport Bitubo treatment front/rear. 🤷🏻‍♂️

The stock front end just doesn't even come close to the Bitubo setup and good tires will make the shortcomings even worse.

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#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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#830 ·
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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#832 ·
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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