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Thread: Kawasaki zxr-E

              
   
   
  1. #41
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    Slowly gaining some weight

    Hi all,
    found some time to assemble the first parts.
    Got the mounting plates in, as well as the Me1115 and mounted the Kelly.
    Found a new place for the latter, which not only stiffens up the setup in left/right but also gets some weight further back and lower, to counter the battery weight a little more.
    The controller will sit right in the former cooling cutout for the exhaust of the ice version. Of course it will need a little notching but otherwise the place seems perfect.
    Even the cables could be used straight from the sachs conversion

    Also found a new home for the CA, loosing some 125 grams of steel brackets of the former rpm and oil temp gauges.

    Gave up on the Domino hall-throttle and did order the standard one instead. Well its a proven product so what.

    Plan for the weekend:
    mount axle and fit in battery.

    stay tuned
    20210226_121220.jpg20210226_121200.jpg20210226_172909 (2).jpg

  2. #42
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    More weight gains

    Well, if it carries on like this it will weight a ton by the end of the week
    Guess i need to put it on a strict diet from now on.

    After getting in the axle into the bike and securing it by two of those clips seen in the pic (anyone care to tell me how they are named- translator only gives out rubbish) it was time to heave the battery in place.
    With the help of my friend Robert this 60kg lump was carried upstairs and dropped in within minutes.
    Front of the battery got screwed into the brackets while the back got a new holder milled and glued on (glue drying atm so this is just temp fitting)
    20210227_114118 (2).jpg20210227_145206 (2).jpg

    Also got the front sprocket mounted and aligned with the chain.
    starting to look like a bike again
    20210228_120032 (2).jpg20210228_120046 (2).jpg

    stay tuned

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  4. #43
    Senior Member Stevo's Avatar
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    Beautiful! Its looking very good.
    I call those "circlips" but I'm not sure what the real name is LOL
    Looking forward to seeing the final weight!!
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: eVOR.v3.4
    WORX.VOR.v3.2

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  6. #44
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    flo, I strongly suspect the ICE in this bike is a stressed member of the frame system. Without the engine bolted in, there may be excess flexing and possible cracking near the welded joint in the main side spars. One way to prevent this from happening would be to add external diagonal bracing between the front engine mount and the ares of the frame near the swing arm pivot. This type of problem showed-up when people were working with some Ninja 250s.
    In place of separate diagonal braces, some people have tied their battery box and motor mounts together; and made them strong and stiff enough to serve the same function.
    Last edited by Electro Flyers; 28 February 2021 at 1345.

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  8. #45
    Senior Member Stevo's Avatar
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    The distance between front and rear wheels elongated on those conversions that Electro Flyers mentioned. Try taking some accurate measurements of distance between front/rear axels to monitor any frame stretching.
    The good thing about the aluminum delta box frame is that its very rigid and strong.
    I suspect you'll know pretty soon on some test rides how much flex you are getting.
    Last edited by Stevo; 28 February 2021 at 1455.
    Current rides: '96 Honda Ohlins VFR, '03 Cannondale C440R, '03 Cannondale Cannibal, '06 Yamaha 450 Wolverine 4x4
    Current builds: eVOR.v3.4
    WORX.VOR.v3.2

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  10. #46
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    Hi
    thanks for your concerns.
    There will be a diagonal brace tie-ing the motormount onto the front holder of the battery, as well as two braces tying the motor mount to the battery. All designed in already. Only i posponed milling it for checking discrepancies between drawing and reality.
    Yes the ICE is a stressed member on this bike, as far as i recall the first production bike using it this way. The brace however, tying the cylinders to the frame, is quite laughable, considering the vibrations the engine outputs ..
    With no rider on it and no riding forces it will be ok for the next 48 hrs, i am sure.

    here:
    v3 013.jpg

    Flo
    Last edited by flo; 28 February 2021 at 1613.

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  12. #47
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    Hi
    been a bit longer than 48 hrs but i got the braces done.
    just enough material left
    20210302_133000.jpg

    perfect fit

    20210303_200110.jpg

    also milled up some holders for the GigaVac and fuse from leftover FG

    20210303_200032.jpg

    stay tuned

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  14. #48
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    Cool It does fit

    HI
    Most dreaded step done.

    After only a slight notching (which had been anticipated)

    20210304_111926 (2).jpg


    Tank fits perfect

    20210304_111835 (2).jpg
    could not be more happy

    even have some room to spare

    20210304_112048 (2).jpg


    Have found a place for the charger , dc and 12V life.
    Charger goes into former 12V battery space, while the aux battery and dc will sit under the back seat. only needing a plate to screw onto.

    20210304_161749.jpg


    Need to find a way to secure the charger... something like on the sachs comes to mind..hmm need to figure that out

    20210304_161801 (2).jpg

    stay tuned

  15. #49
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    Oh my goodness that is sexy!

    Give us a better look at that transfer box - that is some piece of art right there!

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  17. #50
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    Hi
    @Spoonman
    Thanks, will do as soon as there is good weather again.

    Got the tank cleaned yesturday

    20210306_120511.jpg

    And during fine sunday noon got it filled and painted to stop it from rusting again,
    as its on the inside i did not need to worry about paint-run
    20210307_105217 (2).jpg

    received my domino throttle and installed it
    20210306_165449.jpg

    and milled up a new cover for the tank (glued on using a tiny amout of silicone for waterproofing.
    20210306_165539.jpg

    seem 12V is up soon...
    stay tuned

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