Proj3ct z3ro - GSXR.com
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post #1 of 33 (permalink) Old 08-24-2019, 03:50 AM Thread Starter
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Proj3ct z3ro

Hello. my name is Mace.
i like to fix things.
Today i have a total piece of sh1t .....Its a k4 gsxr that has been sitting for about 4 years and is almost too far gone to bring back to life.
In this thread, I will rewire the harness, and try to bring it back to life.
first step. get power to the matrix.
first step achieved. I will have to create a skeleton key for the bike using a 100 ohm resistor.
Then I will get a stock header from ebay and a radiator to make it run.
I joined back in 2005 and have been bringing bikes back to life since then,
Please follow my build and lets see if I can resuscitate another neglected gsxr
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post #2 of 33 (permalink) Old 08-24-2019, 05:59 AM
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Cool project keep us updated
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post #3 of 33 (permalink) Old 08-29-2019, 07:21 AM Thread Starter
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Thanks for checking it out. After some thought, I began to part the bike out. I was thinking i could sell some parts, and keep some parts, and then buy another parts bike and build one from all the free parts. Im not sure if it will work, however there is a large supply of this model lying around everywhere so I will attempt to build one for free by selling parts from one bike and keeping parts from another. Im not sure if it will work or i will have a backyard full of junk but its worth a try.
ill keep this thread updated on the Frankenstein build.

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post #4 of 33 (permalink) Old 09-20-2019, 06:45 PM Thread Starter
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plot twist!2009 gsxr project
wont turn over
feul pump primes
gonna have figure it out
nothing is broken
stay tuned ill get it running'
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post #5 of 33 (permalink) Old 09-22-2019, 07:23 AM Thread Starter
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engine was locked up from the flywheel hitting the stator and probably some rust inside one or two of the bores. I poured some two stroke oil down the bores and removed the stator and plugs and now the engine is rotating by hand. Im not sure if it will run or not, it was crashed pretty hard.
Tried tapping out the flywheel dent, dont think thats gonna work it still rubs. But the engine turns over now when i jump the solenoid.
pics
gonna be a slow build. Good thing is, a whole set of plastics is like 140 to the door. unreal. used to cost 5-600.
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post #6 of 33 (permalink) Old 09-22-2019, 05:24 PM Thread Starter
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It lives.
tapped out the flywheel so it wasnt binding and put a new case cover on just to see if it would turn over with the plugs in. It did. So, I run up to the store grab some oil and throw it in. The bike would only turn when I jumped the solenoid but the fuel pump would prime ....so I figured it was the clutch switch. Ran an old piece of wire between the two leads and the old bitch came to life. Sounded like a bag of hammers for about 20 seconds and was blowing smoke from all the two stroke oil and I almost turned it of because I thought it was gonna blow....then all of the sudden the oil made it into all the passageways and the smoke stopped and it was running good. I checked the battery while it was running, and I am getting no charge, so Ill probably need a new flywheel and stator but I didnt want to buy parts for it if the engine was trash. I warmed it up to operating temp and it began to leak from the radiator cap and oil from under the water pump which I hope is just that oring that goes around the shaft. The 05 garnered enough spending cash to invest into another bike and I still have most of the 05.
I will build one bike for track and one for street. the one for track will just sit in the garage and look pretty because I dont ride track.
Cliffs; it runs
it needs a new rad cap and an oring for the water pump shaft.
also a new flywheel and stator/rectifier
battery
fairings
enough talk
picture time
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Last edited by DEATHWISHRIDERS; 09-22-2019 at 05:29 PM.
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post #7 of 33 (permalink) Old 09-24-2019, 05:05 PM Thread Starter
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Plot twist!'
2009 has a spun bearing.
So, I go out there and see what parts will be compatible with the 05 build.
bingo. fuel pump mates up
bingo gas cap mates up
gonna see if the rad and the exhaust mates up next,then the front master and clipons, although they all have differnet parts numbers, they all mate up. frankenbuild.
than i sell all the parts off the 09 to build the 05!
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post #8 of 33 (permalink) Old 09-24-2019, 06:39 PM Thread Starter
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plot twist.
2005 gsxr just showed up
now going for a dual 05 build, funded from a 2009 part out.
I have a shit ton of parts. Im like a hoarder of gsxr parts at the moment.
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Last edited by DEATHWISHRIDERS; 09-25-2019 at 04:38 PM.
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post #9 of 33 (permalink) Old 09-25-2019, 06:55 PM Thread Starter
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brand new ngk cr9e.
throw some castrol 10w 40 in
lets see some smoke bro..... stva not actuating..... may have to swap out stva from other bike.
stay tuned im gonna get something going.
should see some smoke and fire soon, hope i dont see no gold flakes this time,.
09 blew a fuck!ing rod fml

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post #10 of 33 (permalink) Old 09-26-2019, 05:31 PM Thread Starter
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With these Harley Davidsons I just sand the tank down inside with 80 grit, remove all the factory coating and put the Outlaws back on the road.
With these Jap bikes. you cant fit your hand in there and so I was using the old rocks and sand techique. So, I was thinking there has to be a better way. this tank was the worst Ive ever seen.
I mean it was coated rom top to bottom with thick surface rust. I fired up my 3100 psi pressure washer and stuck the wand in both holes (lol)
next thing you know, no more rust, and no factory coating. just like I like it
bare metal. thats what the fuel likes to live in.
just put a shopvac in it to dy it out add some gas and then sone tw stoke oil and vroom son
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post #11 of 33 (permalink) Old 09-27-2019, 07:25 PM Thread Starter
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I have fuel, spark, and lights
not sure if this old piece is gonna run
stva is not actuating when i turn on key
i tried to to call the geek but he didnt answer
tomorrow i throw somw oil in it and pray to the bike gods..
low bean is not functioning.
fml
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post #12 of 33 (permalink) Old 09-28-2019, 12:22 AM
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You've been busy man!

My father left this Earth for Heaven 5/22/18.
I love you dad, you'll be greatly missed.
I'll always keep on keeping on.

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post #13 of 33 (permalink) Old 09-28-2019, 05:53 AM
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You got rust out using a pressure washer? You lucky.
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post #14 of 33 (permalink) Old 09-28-2019, 06:19 AM Thread Starter
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whatsup fellas, yeah i got kinda kidnapped and was forced to work on Harleys...must have put about 50 back on the road
then i crawled my way back here, and yeah the pressure washer is powerful enough to blast off most of the surface crap, worked alot better than shaking it for hours with rocks and sand in it.
Im hoping to try to fire the first 05 build tonight, I got spark and fuel last night.
The goal of Proj3ct Zero is to build one bike fore free or even for profit by parting out other bikes, in the end you could have a fully built bike for free
It isnt working like I thought it would, but it kinda seems like the idea has potential.

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post #15 of 33 (permalink) Old 09-28-2019, 03:07 PM
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Keep us updated
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post #16 of 33 (permalink) Old 10-01-2019, 07:05 PM Thread Starter
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Will do.
BUILD 05 600B
Today, I had the chance to take apart the original fuel pump that was locked up and begin to clean and reassemble with this KEMSO replacement pump.
I have had some good results with these and for like 25 bucks its a hell of a deal to get your bike runnin'
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post #17 of 33 (permalink) Old 10-04-2019, 05:18 PM Thread Starter
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So, Proj3t Z3ro had some bad luck.
First, the 09 engine blew up, I paid 1000$ for the bike.
Then I go to 600B. I traded a rm250 I paid $500 for. Get the wiring and fuel sorted and fire it up.
Sounds like another bag of hammers. Engine knocking. Not a total loss though, because it has all the parts I need to have a go at 600A which i bought for $500
So, if you are keeping track. Its a 2000 dollar investment.
I go to fire 600A after sitting for many years and it runs fine.
So far about 700 in parts have sold and I have a running bike with full fairing and headlight plus extra tanks cdi's harnesses wheels rotors etc. almost a complete 09 with title and random other parts.
In order for Project z3ro to be successful, I have to make at least 1300 on the remainder of the parts in order to z3ro out.
Anyway, enough blabber here is the pic shortly after 600A and the first fire after several years. I hope to build just one bike now, for profit if it works out.
anybody need cheap parts?
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post #18 of 33 (permalink) Old 10-05-2019, 03:59 AM
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Quote:
Originally Posted by DEATHWISHRIDERS View Post
Will do.
BUILD 05 600B
Today, I had the chance to take apart the original fuel pump that was locked up and begin to clean and reassemble with this KEMSO replacement pump.
I have had some good results with these and for like 25 bucks its a hell of a deal to get your bike runnin'
How many miles have you run those fuel pumps? I bought one also & didn't end up using it. Didn't trust it at all.
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post #19 of 33 (permalink) Old 10-05-2019, 04:50 AM Thread Starter
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I think I saw a video on you tube where technicians compare them to Walbro and the Kemso outperforms the Walbro.
That is enough evidence for me to put one in a bike.
I dont keep bikes long enough to test the longevity of the pump but I wouldnt be scared it would fail any faster than stock.
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post #20 of 33 (permalink) Old 10-05-2019, 11:53 AM
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Quote:
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I think I saw a video on you tube where technicians compare them to Walbro and the Kemso outperforms the Walbro.

That is enough evidence for me to put one in a bike.

I dont keep bikes long enough to test the longevity of the pump but I wouldnt be scared it would fail any faster than stock.
I sometimes tour on my bike so I don't want to be 1000 km from home & had a pump problem. End up putting in a Suzuki Sidekick pump. Which is a Denso.

Unless your bike is not getting enough fuel, I won't put a high capacity pump. Could push the fittings out & lead you stranded. Just my 2c.
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post #21 of 33 (permalink) Old 10-05-2019, 06:04 PM Thread Starter
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Ok my man whatver you say lol

Last edited by DEATHWISHRIDERS; 10-06-2019 at 05:08 AM. Reason: RUDE
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post #22 of 33 (permalink) Old 10-06-2019, 08:45 AM Thread Starter
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Today, I begin the laborious process of removing all the cheap flat black spray paint the PO put on the bike.
I will put a brushed finish on all the aluminum including the frame for a factory race look.
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post #23 of 33 (permalink) Old 10-07-2019, 03:30 PM Thread Starter
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working on brushing the frame.
cant stand polished
hate blacked out.
I do them all brushed
I have a vision for this bike I know you dont see it yet, but I think It will look good.
Now off to see if the 09 swingarm will mount, and throw the front end off the 09 on the bike.
09 reservoir, 09 master, 09 front end, 09 rear end, 09 spare fuel pump etc....
PROJ3CT Z3RO
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post #24 of 33 (permalink) Old 10-10-2019, 05:28 PM Thread Starter
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09 front removed.
will it go on on a 05?
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post #25 of 33 (permalink) Old 10-13-2019, 10:47 AM Thread Starter
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09 front end sold, in accordance with the original philosophy of parting the whole bike to fund the dual 05 builds.
Upon removal and initial teardown of 09 engine, no damage or evidence of top end issues exist.
Like i suspected, with the brass flakes in the oil; it has a spun bearing and is not beyond repair, I may try to tackle that if the head does not sell to fund the 05's
Down to a 700$ balance and have two full 05's. The original plan is still in effect, build one track bike and one street bike for free
fingers crossed I make it to the finish line
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post #26 of 33 (permalink) Old 10-15-2019, 06:17 PM
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I 100% agree, I like the brushed satin finish. What are you using to put that on? On my build the frame isn't polished but it does have some pock marks and scratches from road debris. I'd like to re-do the finish with out polishing. What do you suggest?

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post #27 of 33 (permalink) Old 10-15-2019, 07:15 PM Thread Starter
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Whatsup bro. I started brushing frames many moons ago when I was deep into the Kawasaki zx7. The Factory race teams had a brushed aluminum finish on all the race bikes and Ive since tried to emulate that look on many different models. On a ZX7, you have to first get through the factory coating to reveal the aluminum. On say, a 05 gsxr600 you have to get through the black powdercoat and then the factory coating. I usually use a battery powered impact drill (ryobi) with a wire brush wheel attachment to get through the coatings. When i reach bare aluminum i switch to 120 grit and hand sand the frame in one direction. Thats the closest I can get to factory race look. I cant tell by your pics whether yours has a factory coating, it looks bare.
here is an example of one that looked about right.
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post #28 of 33 (permalink) Old 10-16-2019, 04:22 AM
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Mine is an 89 GSXR 1100. It is bare aluminum. It has been degreased and I was going to use aluminum wheel cleaner on it to brighten it up as well. The forward facing surfaces have nicks and dings I'd like to smooth out...I will practice on the scrap frame until I get it right. Yours looks great! If I get anywhere near that I will be happy. Thank you Sir, I will stop jacking your thread now.

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post #29 of 33 (permalink) Old 10-16-2019, 05:29 AM Thread Starter
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If it is already bare just use sandpaper. Sometmes the wheel can dig grooves. Post pics when you are done Im following your thread. Nice bike.
use a sanding block, i was taught never to use your hand as it leaves warbles in the frame.

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post #30 of 33 (permalink) Old 10-18-2019, 03:55 PM Thread Starter
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So, I go back and pull the engine from 600A. The plan is to sell the head and stator and anything else I can to fund the 05 builds.
Maybe this weekend I will put the good engine into the streetable 600B. Then I will proceed to clean up and paint and have it chilling ready to kill the streets while I build the track/stunt bike.
I have a lead on a 750 engine I may throw into the track bike.
boom. getting used to dropping these engines
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post #31 of 33 (permalink) Old 10-18-2019, 07:21 PM Thread Starter
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dropped engine 600B and ready for transplant. two engine bolts broke, ill have to do some drilling and replace them with new nuts and bolts fml.
now I have a backyard full of junk. Hopefully I can make something soon.
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post #32 of 33 (permalink) Old 10-20-2019, 12:30 PM Thread Starter
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Bad news.
A dude came over to get a part and asked how much?
I said for what?
he said all of it.
project ov3r.
see you guys on the next one
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post #33 of 33 (permalink) Old 11-23-2019, 01:40 AM
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Bad news.

A dude came over to get a part and asked how much?

I said for what?

he said all of it.

project ov3r.

see you guys on the next one


lol. Been in a similar situation. Money talks.
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