ZX7R to R1150 Rockster

After smashing up my 1150 GS up back in may i decided that was it I'm packing up biking.I sold most my gear like panniers, sat navs and other bits and bobs.
But after a month i was getting bored and going in the garage and seeing no bike made it worst, so i thought maybe i was being a bit rash selling up so i spoke to the wife she was happy enough for me to get another bike as long as it wasn't a "SPORTS BIKE" so that was it i started looking quick search on Ebay i found a ........ZX7R "SPORTS BIKE".
I was happy she wasn't

My 1150 before the crash
<a href="http://s934.photobucket.com/user/thomasmonk507/media/gs/2013-04-15141414_zpsda67dc0f.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/gs/2013-04-15141414_zpsda67dc0f.jpg" border="0" alt=" photo 2013-04-15141414_zpsda67dc0f.jpg"/></a>

1600 quid later and a trip to Newcastle i was the proud owner of a 2000 w reg zx7r with only 13000 miles on it.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/Image2_zps8415db62.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/Image2_zps8415db62.jpg" border="0" alt=" photo Image2_zps8415db62.jpg"/></a>

It looked better in the Ebay pictures with the single seat conversion, but on closer inspection it was a right bodge job rear light cluster held in with silicone and the only thing holding the seat unit to the bike was a bit of twisted wire and the seat latch mechanism. luckily he had all the most of the parts to put it back to standard. It had been standing for about 18 months and was badly in need of a service and clean the bloke must have been rubbing and sanding something in his garage because it was covered in dust and muck.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0501_zpsab8b28e7.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0501_zpsab8b28e7.jpg" border="0" alt=" photo IMG_0501_zpsab8b28e7.jpg"/></a>

I soon had it all striped down to give a full detailed clean and change the seat unit over i also fitted a used but uncut rear mud guard and chain guard. Followed by new pads all round and a full fluids change.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0513_zps56cad961.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0513_zps56cad961.jpg" border="0" alt=" photo IMG_0513_zps56cad961.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0509_zps5ee7da18.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0509_zps5ee7da18.jpg" border="0" alt=" photo IMG_0509_zps5ee7da18.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0510_zps3982a81b.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0510_zps3982a81b.jpg" border="0" alt=" photo IMG_0510_zps3982a81b.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0511_zpscc34d839.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0511_zpscc34d839.jpg" border="0" alt=" photo IMG_0511_zpscc34d839.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0519_zpsc87a94a6.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0519_zpsc87a94a6.jpg" border="0" alt=" photo IMG_0519_zpsc87a94a6.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0530_zpsdcc348d0.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0530_zpsdcc348d0.jpg" border="0" alt=" photo IMG_0530_zpsdcc348d0.jpg"/></a<

<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0686_zpsbbae77bf.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0686_zpsbbae77bf.jpg" border="0" alt=" photo IMG_0686_zpsbbae77bf.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0692_zps8764a0c7.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0692_zps8764a0c7.jpg" border="0" alt=" photo IMG_0692_zps8764a0c7.jpg"/></a>

Got her all back together flew through mot got some tax and off i went the mrs still wasn't happy.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/allbacktogether_zpsa36a3f31.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/allbacktogether_zpsa36a3f31.jpg" border="0" alt=" photo allbacktogether_zpsa36a3f31.jpg"/></a>

I only did about 1500 miles before i realised that it wasn't for me id always wanted one from when i first got into biking but i liked the way you could cruise around on the gs you just can't do that on a sports bike so i put her on Ebay and sold her for £1950 so it wasn't all bad

Once sold i started to look for another gs thats when i saw this...<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/KGrHqVHJ8FJdZwvJBhBSZoUFnsw60_12_zps8e00cb18.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/KGrHqVHJ8FJdZwvJBhBSZoUFnsw60_12_zps8e00cb18.jpg" border="0" alt=" photo KGrHqVHJ8FJdZwvJBhBSZoUFnsw60_12_zps8e00cb18.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/T2eC16FHJIQFHHScCB4BSZoU9In5w60_12_zpsb56436d8.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/T2eC16FHJIQFHHScCB4BSZoU9In5w60_12_zpsb56436d8.jpg" border="0" alt=" photo T2eC16FHJIQFHHScCB4BSZoU9In5w60_12_zpsb56436d8.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/T2eC16JHJGsFFMeIimrlBSZoU7wKEg60_12_zpseae3db5d.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/KGrHqQOKpMFJWOgBYrBSZoU9hIl60_12_zpsc3f43931.jpg" border="0" alt=" photo KGrHqQOKpMFJWOgBYrBSZoU9hIl60_12_zpsc3f43931.jpg"/></a>
Balderston in Peterborough had it on Ebay as a part ex. I went down to have a look before i put a bid in,it was a bit rough had been dropped on the right hand side which is why i think it had that god awful head light fitted but it had service history and only 15000 miles.
Well i won it for only £2601 bit of a bargain i think when you look at the price of 2003 twin spark gs's which have all got moon miles.
Went down to pick it up and got chatting with one of the workshop mechanics who said he used to have a rockster and nearly bought this one,then he said "I've got a headlight and all the bits you need to sort the front end out you can have it all for a £100 if you want it"
he even came round the house and wired it all in and got some extras as well such as front and rear seat and a full dash with speedo and rev counter all for £100 and a few cups of tea.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0196_zps8d3f9783.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0196_zps8d3f9783.jpg" border="0" alt=" photo IMG_0196_zps8d3f9783.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0219_zps67e563d1.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0219_zps67e563d1.jpg" border="0" alt=" photo IMG_0219_zps67e563d1.jpg"/></a>

So started the strip, clean paint and renew.
The front headlight cover had a scuff mark where a screen had been rubbing on it thought it would not be worth paint because of the cost of paint so i bought some of that carbon wrap £5 for a sheet off ebay never done it before but thought it was worth ago.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0247_zps7aa3f68b.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0247_zps7aa3f68b.jpg" border="0" alt=" photo IMG_0247_zps7aa3f68b.jpg"/></a>
After
<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0252_zps32749c56.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0252_zps32749c56.jpg" border="0" alt=" photo IMG_0252_zps32749c56.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0251_zpseee2cd66.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0251_zpseee2cd66.jpg" border="0" alt=" photo IMG_0251_zpseee2cd66.jpg"/></a>
Didn't turn out to bad i think certainly cheeper than painting it and it goes quite well with the carbon front mudguard its already got.

Next i had had a go at sorting the rocker covers they had been badly painted black to try and hide the damage to the right hand side but it was a really bad job thought about buying new ones till i saw the price!!!<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/KGrHqJHJCoFJFgkOS5BBSZoU-Ud2w60_12_zps0cb60853.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/KGrHqJHJCoFJFgkOS5BBSZoU-Ud2w60_12_zps0cb60853.jpg" border="0" alt=" photo KGrHqJHJCoFJFgkOS5BBSZoU-Ud2w60_12_zps0cb60853.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0271_zpsdad63403.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0271_zpsdad63403.jpg" border="0" alt=" photo IMG_0271_zpsdad63403.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0292_zps68b6cf18.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0292_zps68b6cf18.jpg" border="0" alt=" photo IMG_0292_zps68b6cf18.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0298_zps189a1e84.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0298_zps189a1e84.jpg" border="0" alt=" photo IMG_0298_zps189a1e84.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0300_zps0465bd52.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0300_zps0465bd52.jpg" border="0" alt=" photo IMG_0300_zps0465bd52.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/beforeafter_zpsc330451f.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/beforeafter_zpsc330451f.jpg" border="0" alt=" photo beforeafter_zpsc330451f.jpg"/></a>

Nice Job

Cracking bike and very under-rated

Health to ride

Next job was to address the flaky paint on the forks and the gravel rash on the front engine cover. thought it would be easer if the exhaust headers were out the way plus that need a good clean and polish.
What mistake got three of the exhaust nuts off but the last one sheered off


<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0312_zps8fa71f61.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0312_zps8fa71f61.jpg" border="0" alt=" photo IMG_0312_zps8fa71f61.jpg"/></a>

Oh well ill just use an extraction tool that didn't go well it snapped in the stud
So it was off with the head and down to the local engine builders to have it spark eroded and remove the other stud whist there at it.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0315_zpsdbbd9777.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0315_zpsdbbd9777.jpg" border="0" alt=" photo IMG_0315_zpsdbbd9777.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0313_zps8bb0aeda.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0313_zps8bb0aeda.jpg" border="0" alt=" photo IMG_0313_zps8bb0aeda.jpg"/></a>

Got a bench polisher for xmas so i set about the exhaust.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0348_zps61ecd616.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0348_zps61ecd616.jpg" border="0" alt=" photo IMG_0348_zps61ecd616.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0349_zps0b9ee585.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0349_zps0b9ee585.jpg" border="0" alt=" photo IMG_0349_zps0b9ee585.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0354_zps02798df4.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0354_zps02798df4.jpg" border="0" alt=" photo IMG_0354_zps02798df4.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0355_zps2817ae44.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0355_zps2817ae44.jpg" border="0" alt=" photo IMG_0355_zps2817ae44.jpg"/></a>

Got round to painting the forks and engine decided to go for hammerite satin smooth black on the forks instead of the blue easer to get hold of and cheaper plus it goes well with black engine and matt black tank but mostly because it was cheaper.
<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0367_zps52326613.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0367_zps52326613.jpg" border="0" alt=" photo IMG_0367_zps52326613.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0358_zpsf63a1465.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0358_zpsf63a1465.jpg" border="0" alt=" photo IMG_0358_zpsf63a1465.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0357_zps718b7784.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0357_zps718b7784.jpg" border="0" alt=" photo IMG_0357_zps718b7784.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0361_zps91f76d4b.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0361_zps91f76d4b.jpg" border="0" alt=" photo IMG_0361_zps91f76d4b.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0371_zps7cbb6efa.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0371_zps7cbb6efa.jpg" border="0" alt=" photo IMG_0371_zps7cbb6efa.jpg"/></a<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0369_zps60549db1.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0369_zps60549db1.jpg" border="0" alt=" photo IMG_0369_zps60549db1.jpg"/></a>
Fitted a new stainless bolt kit for the engine case and a fender extender to try and stop the rash coming back.
This is how she looks now until i get the head back.<a href="http://s934.photobucket.com/user/thomasmonk507/media/zx7r/IMG_0400_zps4a203be9.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/zx7r/IMG_0400_zps4a203be9.jpg" border="0" alt=" photo IMG_0400_zps4a203be9.jpg"/></a>

Excellent job(s).

Great Work!

project

Yes, it's a from me.....Nice job......

Lovely

You've done a cracking job there fella, I always loved the look of the ZX7R but as a fat 50+ codger I don't reckon it would suit me. The rockster also looks lush!

rockster

Crackin job

Well done fella it looks good.

Congrats mate. Looks great, keep up the good work

Rocker Cover Finish / Drill Guide

I will be repainting my rocker covers when I check the valve clearances, yours look excellent is it Hammerite Satin you have used? And new bolts?

Also attached is pic of a drill guide my neighbour who is a good engineer kindly helped make up to remove two sheared and stubborn exhaust studs.
This was after we'd tried welding rods on, and every kind of thermal shock treatment, eventually opting for carefully drilling out and cleaning the threads.
I see yours sheared off flush, fortunately we were able to save the last couple of turns of thread which the guide turns onto and let us drill well down through the stud before opening up with larger bits.

I would be happy to lend this by post if anyone else is stuck with similar problems.

Nice job.
What did you use to get the gearbox casing and shaft drive casing looking like new again?
Cheers.

Thanks for all the comments,your right its hammerite smooth satin i used on the rocker covers and i used silver hammerite on the bolts had some left from the gs's silver bits thought about buying new till i saw the price

For the gearbox and driveshaft i just gave it a good wash followed by autoglym polish then autoglym hd wax but I've since bought some of that sDoc colour restorer which is really good used some on my mates triumph that we doing up at the moment with good results.<a href="http://s934.photobucket.com/user/thomasmonk507/media/triumph_zps0284051b.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/triumph_zps0284051b.jpg" border="0" alt=" photo triumph_zps0284051b.jpg"/></a>

Unlike the silver engine and gearbox cases which are (heavily) powder-coated, the black ones are painted (thinly). The paint will polish/wear through in no time. It's easier to remedy with satin black than the silver powder-coat (though I've recently found that Halfords own enamel silver is a good match).

Brilliant job , excellent bike I had one and sold it when I bought a gs ....wish I had kept it !

Got the head back last week and now its all back together.<a href="http://s934.photobucket.com/user/thomasmonk507/media/IMG_1371_zpsf6bd2136.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/IMG_1371_zpsf6bd2136.jpg" border="0" alt=" photo IMG_1371_zpsf6bd2136.jpg"/></a><a href="http://s934.photobucket.com/user/thomasmonk507/media/IMG_1380_zps5548808d.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/IMG_1380_zps5548808d.jpg" border="0" alt=" photo IMG_1380_zps5548808d.jpg"/></a><a href="http://s934.photobucket.com/user/thomasmonk507/media/7dc53f5b-9a87-449b-bad4-e937e985cbd4_zps59cca741.jpg.html" target="_blank"><img src="http://i934.photobucket.com/albums/ad189/thomasmonk507/7dc53f5b-9a87-449b-bad4-e937e985cbd4_zps59cca741.jpg" border="0" alt=" photo 7dc53f5b-9a87-449b-bad4-e937e985cbd4_zps59cca741.jpg"/>