Race Bike Build

Here's my build article. The objective was to set up my 2012 ZX6R as a race legal bike with as little done to it as possible and as little permanent modification as possible. I didn't bother throwing a lot of performance parts at it rather I focused on meeting the OMRRA requirements as simply as possible.

After my Ninja getting stolen and dropped on both sides, then crashed at RMP when someone did a bad pass and dropped anchor in front of me, it was looking kinda rough.

Starting condition, more or less complete but banged up fairings. As I started taking them off I found that they were held together more or less by friction and a lot of the connectors were broken, I guess I won't be putting them back on.

Front End all Naked

Test Fitting the front/top fairing. I went with MotoAndes due to price and construction. For $400ish shipped you get fairly tough fiberglass fairings that allow use of the kickstand.

I watched a ton of the videos from Sportbike Track Gear that show how to drill and fit race bodywork. I would have sucked at this part much worse if I hadn't. More or less the drill dots on the fairings were right on. The places where they weren't it was due to bits and pieces of additional equipment like the case savers that added extra bulk. The main thing I learned here is measure three times drill once, and use a unibit. Also don't work on a bike with low blood sugar (something I struggle with).

I was pretty sloppy getting the belly pan holes and the corresponding holes drilled right. Something to make better over the winter. Because of this my Dzus fasteners like to vibrate loose....

Quick rattle can job. I was interrupted by the rain and ran out of paint. The upper looks bad.

I relocated the regulator rectifier to where the headlight used to be.

Half done fairings. I took it to New Racer School like this.

Lever guard installed. It would later vibrate loose and I'd loose half of it.

Little things like this lock have to be removed. I don't want to permanently modify anything so it took some work.

Test fitting the tail. Actually installing the tail was easier than the rest of the fairings.

Installing the case protectors was mostly pretty easy. Pull out half the bolts, install the cover, reinstall new bolts with LocTite.

I ordered an aluminum bolt for the coolant drain by mistake, then broke it and had to remove my water pump to extract it. Dumb dumb. Bought a titanium one and installed that. This was one of those frustration moments where I really really wanted to quit.

Out with the green, in with the pink (water wetter). This took a long time to flush all the green out. It was messy and frustrating as well.

I used stencils to put my novice race number on the tail. When I go back in the winter to do the paint properly I'll paint it like a number plate or whatever.

Safety wiring. I used as many pre-drilled Pro-Bolt bolts as possible because I am awful at using power tools.

Then there was this thing. As soon as I opened it I realized that they want you to drill into the underside of the swingarm and tap the holes. Um, no. I ended up getting one from a racer that works with sheet metal that goes on with the spool.

More Safety wire.

Had to drill this one. :( Broke a drill bit on it.

After my multi piece guard failed on the Friday trackday I bought this one piece Bonamici guard which is sexy.

Nobody likes to admit how much they spent on this silly hobby, so lets do that.

Fairings - 450ish (purchased MotoAndes)

windscreen - $22 (ebay) + $10 bolts

oil drain bolt, oil fill bolt (moto-d) $46

pinch bolts, radiator drain bolt (pro bolt) $38+15

safety wire washers (pit posse) $10

safety wire/pliers - 25

drill bits - $7

unibit - $35

lever guard (gratis from DW15)

lever guard to replace the one that fell apart because I didn't loctite it (Bonamici ) $139

case protectors 105 (purchased yana Shiki)

water wetter $10

Oil filter with safety wire hole (k&n) $5

oil $30

dzus fasteners $32

Fork Seals: $26 + $195 service cost (I'm going to have to re-do this because the shop screwed it up!)

toe deflector - 60 (required drilling, didnt use)

no drill toe deflector from Jason Iverson- $40 

vinyl numbers - $20

Total so far: $1320

Things to note. This took me about 40 hours mostly working in the evenings after work. I'm not a great mechanic so these things took me a lot of time, effort, and frustration. A good mechanic that had done a race bike build before could have done this in, maybe 8 hours? This also could have been done cheaper if I was good at drilling things and drilled OEM bolts instead of buying ProBolt. I could have used one of the beat up OEM windscreens I have to save a few bucks. Its tough to find a serviceable used fairing kit for the price of the MotoAndes kits, so that'd be a hard place to cut cost corners effectively. For my first race round I used the DOT tires instead of using slicks. I'll probably stick with DOTS for the next round as well to keep the learning curve down.