Kawasaki ZX6, ZX7, ZX9 Supersport and Superbike
Setup tips from Mike Preston, Team Manager, Kawasaki Racing USA

By Jim Gianatsis

When it came to checking on performance modifications and upgrades for Kawasaki's popular ZX lineup of Sportbikes to include here in Paddock Garage, I didn't have far to go. I, myself, had built up highly modified versions of the previous Generation One and Two, ZX7s which even appeared in early editions of the Fast Dates Racebike Pinup Calendars. And along the way I got many of my performance parts and tuning advice from Rob Muzzy, then Kawasaki's contracted Superbike and National Championship winning race team. In year 2000 Kawaski USA corporate management made the decission to bring their race team in-house, placing former Kawasaki R&D development technician Mike Preston in charge as Team Manager. Mike and I are old buddies going back to 1981 and 1982 when Mike was a Pro motocrosser sponsored by Moto-X Fox where I worked at the time in Fox's product development and advertising. Mike and his girl friend even modeled for me in the Moto-X Fox apparel catalogs.

I gave buddy Mike Preston a call to find his setup tips for the Kawasaki factory Supersport and Superbike models. You'll be happy to know you aren't going to have to spend a lot of money on these bikes, if only because there's not a whole lot you and Team Kawasaki can do under AMA Supersport rules. We should make note here that all the modifications mentioned for the ZX6 (600cc) and ZX7R (750cc) AMA Supersport class bikes can also apply to the ZX9 (850cc) and ZX12 (1200cc).
ZRX HANDLING IMPROVEMENTS
"Everything we do to our Supersport bikes is pretty much bolt-on," said Mike. "The place we go for suspension is Ohlins. We run an Ohlins Rear Shock, together with an Ohlins Front Fork Internal Damping Kit. For Supersport we have to keep the stock forks, but you can change or modify the internals.

We think Ohlins offers the best Fork Kit on the market, particularly with their experience in building racing forks for the majority of factory bikes in Superbike and Grand Prix."

For less resticted racing classes, Superbike and high performance streetbike applications, Ohlins also offers its somewhat affordable complete Fork Assemblies which for about $3,000 which will bolt right onto your ZX bolt with the stock Nissin brakes. Mike also recommends using a better feel steel braided brake line kit like from Goodrich which one of the team's sponsors, Lockhart-Phillips provides to them.

Ohlins Suspension components are availalbe from any local motorcycle dealer who can order them direct from US distributor Part Unlimited. Parts does not sell retail direct. If you need help setting up your Ohlins suspension, the most knowledgeable Ohlins dealer and race suspension tuner in America is Stig Petersen at PPS Suspension

A worthwhile and very cost effective suspension upgrade, though is the Ohlins rear shock. The Japanese have never built a worthwhile production rear shock on a sportbike, and Ohlins is the sport's standard for tuneability and handling performance. We've never riden a stock revalved shock that is as good as a bolt-on Ohlins or Fox Factory Shox.

Another serious handling improvement for street or track (but not legal in Supersport) is a set of magnesium racing wheels. Team Kawasaki runs the popular Marchesini wheels which are found on nearly all the top factory superbikes. Some US teams like Honda's Erion Racing use the new Performance Machine cast magnesium wheels, duplicating the stock wheel sizes of 3.50 x 17 front, 6.00 x 17 rear.

You can expect to save some 5 pounds with the front wheel, and 10 pounds at the rear. Mag wheels are an important performance gain on any sportbike because they not only reduce weight for better handling, but they also improve braking and acceleration.

And the improved power-to-weight performance gain that magnesium wheels provide for improved acceleration, braking and handling are more important and more cost effective, dollar for dollar, than any internal engine modifications which always come at the cost of engine reliability and rideability. Marchesini wheels are available in America from T.A.,W. Vehicle Concepts, Lakewood., Colorado, phone: 888-235-0910. A pair will set you back about $2,000 plus new Supersport tires and balancing, bringing the cost closer to $2,500 when your're done.

More good reading...

Racing Suspension Setup and Tuning
Basic Suspension Setup and Tuning
Advanced Chassis Setup and Tuning
Suspension Operating Theory


Marchesino Wheels, Brembo Racing Brakes
T.A.W. Vehicle Concepts
#107, 12860 Cedar Drive
Lakewood, Colorado 80228
http://www.tawvehicle.com
Phone (1) 1.888-235-0910 toll free USA
Phone (1) 1.303-984-9999
Fax (1) 1.303-969-0276

Akrapovic Exhaust Systems, Goodrich Brake Lines,
Performance Machine Wheels and Brakes

Lockhart Phillips USA
P.O. Box 4802
San Clemente, CA 92672
http://www.lockhartphillipsusa.com
Phone: (1) 800-221-7291 USA
Phone: (1) 949-498-9090 International


ZX7,9,11,12 Engine Big Bore Kits, Pistons, Cams
Superbike Mike
2928 NW 17th Terrace
Ft. Lauderdale, FL 33311
http://www.superbikemike.com
Phone:954-484-6969

Ohlins Suspension Components and Setup
PPS Suspension
Unit 6, 4065 East Lapalma Avenue
Anaheim, CA 92807
http://www.ppsracing.com
Phone:714-630-4777

Factory Tuning Jetting Kits,
Keihin FCR41 Racing Carburetors

Sudco International Corp
.
3014 Tanager Avenue
Commerce, CA 90040
http://www.sudco.com
Phone: 323-728-5407

Kawasaki ZX Engine Performance
MUZZY RACING
, USA

http://www.Muzzys.com
Phone: 541.385.0706

ZRX POWER IMPROVEMENTS
for the Street and SuperSport Racing

"On both our AMA ZX6 and ZX7 SuperSport bikes, and on our factory Superbikes we run Akrapovic exhaust systems," explains Mike for improving engine performance for the ZXers. "Akrapovic exhaust systems also availble through our team sponsor Lockhart-Phillips, who is the sole US importer of Akrapovic."

Akrapovic is one of the few avaialble sportbike exhaust systems on the market which feature tapered header bikes, which increase in diameter from the engine's exhaust port header flange down towards the collector. This is a much more expensive exhaust system to build because it requires much more fabrication and welding than other, lower priced systems, but the increasing diameter of the tuned Akrapovic system helps pull burned exhaust gasses out of the combustion chamber, and it sends back a stronger sonic wave to the engine to hold in the incoming fresh fuel charge during valve overlap.

There is a reason why every top factory Japanese bike team in World Superbike uses an Akrapovic System. While in AMA Superbike, sponsorship deals and marketing of a team's own proprietarty brand of exhaust sees many different exhaust system brands being run, but you can never be sure that what you see on a factory SuperSport or Superbike is what you, the customer, can really buy. Except in the case of Akrapovic.

CARBURETOR RECALIBRATION
If you modify your bike's intake or exhaust system, you must rejet the bike or it will make less power than stock. This was an easy question. Whey I asked Mike if their SuperSport bikes ran trick jetting from the factory in Japan, or what not, he said no. That the team's top race tuners like Crew Chief Al Ludington buy both the popular Factory Tuning and Dyno Jet jetting recalibration kits. Then they'll run one brasnd kit or the other, or perhaps mix parts from both, or do a little cutting or sanding on a needle or needle jet.

The team's advantage in being able to dial in the perfect jetting for each bike, of course, is the fact they have an in-house dyno to run and test the jetting changes on, plus many days of testing and practice out at the track.

For the rest of us though, just buy a good jetting recalibration kit and follow the kit's set-uo suggestions for the modifications you are running on your bike. I favor the Factory Tuning Jet Kits because they provide free phone-in tunig assistance, and they keep detailed records on what setting work best with which model bike and it's modifications for your local race track or geographical location. And it works!

Visit the Paddock Garage Carburetion Section for complete carb tuning tips and information on where to order Recalibration Kits.

KEIHIN FCR41 CARBURETION
The factory Kawasaki ZX7RRs run Keihin FCR41 smoothbore flatslide carburetors. These aren't necessary for a stock motor run on the street, but if you are roadracing or running a heavily modified engine with cams, high compression pistons and porting, the FCRs are the next step. Sudco International is the main Keihin distributor for North America and they can set you up with everything you'll need.

ENGINE MODIFICATIONS
If you're running a ZX6 or ZX7R in Supersport, then you can't do any internal modifications to the engine, including no porting, polishing or any removing of metal, anywhere. Where Team Kawasaki and the other factory teams have you beat, though, is in their parts warehouse. There they can measure and find the parts that offer the highest compression, best port flow, best alignment and tollerances to reduce friction and increase power, while still remaining within factory production specifications. It might only add up to a 2-3% power increase over your store bought bike. But then put one of the top factory riders in America like Eric Bostrom in the saddle of that bike, and you're much better off staying back home at your local track.

If you are running your ZX in a Superbike or Formula Extreme class, then modifications to the engine or pretty much unlimited. I asked bike if Kawasaki USA offers any performance parts to its customers.

"Unfortunately not. Our SuperSport bikes are allowed so few modifications we just run the aftermarket parts I've told you about.

For the factory Kawasaki ZX7RR AMA Superbikes that Eric Bostrom and Doug Chandler race, those are complete race bikes sent to us from the factory in Japan, ready to go. All of our spare parts come from the factory and really aren't available for sale."

Of course, in theory, some where in the world there needs to be 300 of these factory ZX7RR race bikes or complete kits to homologate the ZX7RR for AMA and World Superbike. But until we can come up with $120,00 to order one for ourself (at twice the price of works Ducati 996RS that wins more races), you'll never know where those other ZX7RRs might be. And the other factory race teams don't throw stones because they also live in glass houses.

For those who do want more power, there is Muzzy's, still recognized as America's premier performance shop for Kawasaki bikes. Rob will be able to help you out with more serious modifications including hi-compression and big bore piston kits from Weisco and J&E, plus cams and headwork to get you up to competive factory Superbike power.

After all, Muzzy's is the only team to have given Kawasaki it's one World Championship and was it 3 AMA Superbike National Championships?



 

 



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