ZX9 Front End Swap

[woodcreekpete]

Just getting started on swapping this 94 front end onto the FJ. So far, everything seems pretty straight forward. A few things about the ZX9 make it quite a good donor:
1. Leg length is 30" from under the cap to axle centerline. My 92, deducting the stub length for the clipon, measured 30" as well. ZX9s mount the clipons above the triple so they need to use longer legs.
2. Speedo drive is mechanical - not sure if the reading will be the same though but it hooks up fine.
3. Stock springs, according to Racetech, are 1.05. Probably they've lost a little pep over the past 26 years but until finances allow for a rebuild, they should be a big improvement over the standard issue FJ springs.
4.Spokes have the same profile as stock or the GSXR rear on mine.
5. Fender's a reasonable shape - looks like it belongs on there. I trimmed it a bit to try to mimic the FJ's shape a little.
  The machinist figures he can make some new caps with a built on stub to use the original clipons.
Only other things needing attention will be the fork stops and possibly main switch clearance of the gauge surround.
So far, so good.

[Waiex191]

Nice!

[Millietant]

Looks great Pete.

You haven't mentioned the stem or triple trees - is everything stock ZX9, or have you pressed in a FJ stem, are there any other mods to make it all fit (lock stops, steering lock, ignition switch mounting etc).

When those bikes were new, Kawasaki seemed to have a reputation for having the best front ends around...... seems like a great choice

[2big]

Wow Pete - a very tidy front end - are the callipers ZX9 tokico or are the centres the same to accept your exiting FJ / blue spots
(Quite like the workshop trolley too! I need one of those)

[woodcreekpete]

The stem's out of the FJ. The machinist didn't like the idea of welding the stem so he made a bush to fit it together. Top triple's off a ZX7. The ZX9 top triple raised the legs about a 1/2". One of the ZX Forums suggested the ZX7 part. Needed another bush for the stem diameter. I made a steering stop - it works fine but is best hidden down there. Been riding off and on for 50 years and have never used a steering lock so I didn't try to make it work. A little filing on the FJ ignition switch mounting screw holes and minimal trimming of the loop on the triple and the switch fit up easily.
I like the look of the FJ clipons so once again, Tony the machinist came up with an idea. I love the guy - he thinks in ways I don't. Anyway, he turned down and threaded the leg caps to take the adapter in the pics. The wide part is the same diameter as the fork legs and will be in the top triple about 8mm - maybe more or less depending on the fork length. Once the fit is finalized, the fat part will get turned down to sit flush with the triple and the clipon stubs will be cut a similar amount.
Cut the mounting tabs off the clipons and made new ones to use the existing holes in the triple.
There's still access to the pre-load and the damping adjustments. Ton's gonna whittle a couple of nice Delrin caps, everything will get painted satin black.
Into this for about $300, not including how much I overpaid for the ZX9 (money was burning a hole in my pocket). Cheaper to buy the whole bike though than source parts bit by bit.
Next up, gonna try and fit a BMW Dakar shock. It's a bit longer but is rebuildable, has remote preload and both damping adjustments.

[Pat Conlon]

 

What year ZX9? Looking at the axial mount calipers I would say pre 2004

[woodcreekpete]

It's off a '94. Not sure exactly when, but Kawasaki went back to the old style forks in the late '90s on the ZX9.

[Pat Conlon]

Nice Job Pete! Please take lots of pictures for us. After the dust settles we can do a write up for the Suspension Files.

Cheers

[woodcreekpete]

Front end is pretty much finished now. Eddy the welder did the tabs on 2 sets of clipons - just in case of some unfortunate event.
The adapters were milled back 8mm so the legs sit 10mm down into the triple. I cut the center out of the original ZX9 triple and had it welded to the underside of the ZX7 part. Probably didn't need to do it but it's a little more support for the tops of the legs. The adapters were Loktited to the leg caps and everything was buttoned up. With the preload dialed back to nothing, there's 20 1/4" from the bottom of the triple to the axle centerline - 20 1/2" is about stock with preload in. Static sag is about 20 x 25mm.
I had a pair of specimen jar masters on it but it was looking way too busy for my taste. Plus, the ZX9 master is the same bore as the FJ so both the stock ones went back on. Nice and tidy now, although the top triple is kinda plain looking.
Did a little playing around with vinyl striping and had the Yamaha logo stretched to fit under the headlight. $10 for 4 logos, made while I waited - can't beat that. It makes it much easier to make the side stripes on the fairing when the vinyl doesn't have to wrap under the headlight. Side stripes are going to come a bit forward and the logo might get redone a bit wider but that's pretty much the look.
  It's coming along!

[Millietant]

Looking Good, Pete.

The seat goes really well with the black paintwork too, I like it a lot 

[fj1289]

Nicely done!  Can't wait to here the ride report

[Pat Conlon]

That looks great Pete! Very well done!  

Jan asked a good question:

....are the centres the same to accept your existing FJ / blue spots?

I'm partial to the one piece Yamaha monoblocks over any 2 piece caliper.

[woodcreekpete]

Sadly, the blue dots are gonna have to stay in the milk crate. I tried a set of 6 pot Zx7 calipers but they won't bolt up either. It's not that the stock brakes are shitty - I'm sure they're more than up to the task, especially considering the sloth-like way that I ride.