Almost finished DZUS fasteners

Well when I came to fitting the upper fairing with the DZUS fasteners I couldn't lip them over the edge of the fairing due to the holes being to far in, but after some research the fitting seem to be fitted either lipped over the fairings or simply positioned over the hole - which is what I tried to do, this didn't turn out as planned because using this method it makes the whole thickness 3-4 mm thicker, so the male parts were too short - Where have I heard that before :-)

I ordered some longer male parts but even these didn't do the job for some reason as there angle of attack was to abrupt and they got stuck on the females.... In the end one of the Gamma listes suggested I notched the fairing to be able to place the females over the edge of the fairing - this worked a treat and so now the upper fairings are now complete.

Kevlar clutch

Hi All,

I wanted to try Kevlar clutch plates in the RG, and as the only source seemed to be from RG500.com at $120, problem is it is very expensive to ship from the US, so I thought I would try and find the equivalent at EBC in Europe. I had read that the ZX6R clutch plates were similar, so looking at the EBCbrakesDirect site for both the RG500 and the ZX6R you find the same reference in standard clutch plates, but no reference for the RG.

Being as the standard clutch plates are the same, the logic goes that the Kevlar ZX6R ones would also fit, so I ordered a set. Unfortunately they only seem to sell them as a kit with the springs, which are not at all the same, probably twice as long, anyway this morning I took the RG clutch down, and compared the plates. Almost exactly right, although the ZXR ones are 143 in overall diameter versus the RG plates at 141mms. On installing the plates I can confirm that they do seem to fit, and do not rub at all. The other difference is that the ZXR plates have a notch cut out of every third tab, but I don’t think that is of any consequence. For reference the Kevlar plates come up around 2.8mms in thickness, and there are nine in the kit.

The reference at EBC for the kit including springs is : SCR 038 and I ordered mine here :-

http://www.ebcbrakesdirect.com/bike/parts_clutch.asp?part=clutch&make=KAWASAKI&model=500to750&year=ZX%2D6R+%28ZX+600+G1%2FG2%2FJ1%2FJ2%29+%2898%2D01%29&sec=

for 90 pounds plus shipping. Given current exchange rates this is probably more expensive for America, however this is cheaper that getting the RG500.com ones shipped.

So they are in the bike now, I just need to find a suitable oil, and I will be able to test my new clutch.

Programme for 2011 book your diaries!

The calendar for 2011 has been published on the ProClassic site :-
Health permitting, my name is down for all the races, I will see if I can find a partner for the endurance races.
- 2/3 April  Nogaro
- 30/1May Croix en Ternois
- 18/19 June Magny-Cours
- 9/10 July Pau
- 23/24 July Le Mans
- 10/11 September  Ledenon
- 1/2 October Croix en Ternois

Grand Prix Endurance Classic :
- 23/24 April Carole
- 1/2 October Croix en Ternois

Dzus Fasteners

Hi all, I started to fit my DZUS quarter turn fasteners at the weekend. I bought 14mm long ones with a riveted female part. I chose the riveted type because the holes in the fairing are not all at the right distance from the edge of the fairing to be able to use the clip-on type. Using the riveted type you can have the choice of either sliding them over the edge of the fairing or placing where you like on the fairing so that both “female” parts are on one side of the fairing.

I wanted to try to use the same holes as my old screw in fasteners, so this required that I removed the captive screw-in female part. These are kind of crimped to the fairing, I imagine that when they are installed they go through a fixed size hole and then some tool is used to squash them so that they can no longer escape through the hole. So to remove them you have to cut off the oversized part so the remainder will go through the hole. First off I thought I would simply drill the large diameter part off, but this proved difficult because as soon as the drill bit caught on the brass fitting it simple started turning in the fairing, and wearing away the fairing, so I eventually used the cutting wheel on the dremel to cut away the  “head” of the female part, this worked OK, but I made a few marks on the fairing which will need touching up with black paint – I started on purpose on the lower part of the fairing where the fasteners are hidden from view!

With the old female screw part removed, I needed to line up the female DZUS part, and drill 2 small holes the same diameter as the pop rivets supplied with the fittings.  After drilling one hole I pop riveted the fastener on so that I could use it as a guide for the second hole, this worked pretty well, and the female part of the DZUS fitting is securely fastened to the fairing. In order to fit the male part, I simply used a 7 mm drill to bring out the hole size to fit the male part through. It’s very difficult to stop the paint and top gel coat splintering with a new drill (I didn’t have a 7mm drill), so next time I will try enlarging the diameter with a file, or stick some tape on the area to hold things together. You need to fit the first nylon washer then push the part through the newly enlarged hole, and then fit the second washer, this keeps the male part in place even when undone. I fastened the two fairing halves together using the three fasteners I had completed, and off the bike they seem to hold the fairing halved together pretty well. Next I have to attack the upper halves, and it will show if I bugger it up so I will take it carefully.

I also received in the post today two SteadyStands which I will be using in the van to hold the front wheels of the bikes. They came from a company AKXION in France near Ales (circuit) who distribute all sorts of interesting stuff to hold bikes. They gave me a small discount for racers, and the products were exactly as they said they would be. I have already put them together as you can see from the 2 photos, which was pretty easy.