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Discussion Starter #1
Hello,
is there anybody with a 900RR (1993/1995) who's got a different fuel tank on their bike???
Anybody got a carbon / Keflar fuel tank?
 

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Only the front mounting point...

Bzzzzzzzzzzzzt.................... WRONG!!:p

Actually, the 96-99 tank has a completely revised profile and overall design, as well as a slightly different capacity.

The story is that too many 'little guys' complained to Honda that they couldn't fit on the bike - it was too big for them. So Honda revised the tank design. Overall, it's smaller, shorter and less 'bulbous'.
 

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Discussion Starter #8
Bzzzzzzzzzzzzt.................... WRONG!!:p

Actually, the 96-99 tank has a completely revised profile and overall design, as well as a slightly different capacity.

The story is that too many 'little guys' complained to Honda that they couldn't fit on the bike - it was too big for them. So Honda revised the tank design. Overall, it's smaller, shorter and less 'bulbous'.
thanks! Does the 96-99 tank fit nicely in a 93 bike still?
 

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Dunc, it fits fine and looks great. It does require a small amount of fabrication (gotta make a small aluminium plate and drill/tap the frame - which is super easy), and you'll need to buy the mirror stay from the '96-'97 Fireblade.

Have a look at the '99 tank on my '95 945RR. The 93-95 frames were identical, so you can see how it looks:

http://i108.photobucket.com/albums/n19/simon-richards/profile8x6.jpg
http://i108.photobucket.com/albums/n19/simon-richards/frontside8x6.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tank2.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tank.jpg
 

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Discussion Starter #10
wauw looks great Sime, less bulky!
Very nice bike too.
I was a bit scared it will leave a bit of a cap between the saddle and the tank because I thought the tank is bit shorter but it seems okay.
Thanks for the info and the pics.
Why do I need to make a small aluminium plate?
Dunc.
 

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Dunc, it fits fine and looks great. It does require a small amount of fabrication (gotta make a small aluminium plate and drill/tap the frame - which is super easy), and you'll need to buy the mirror stay from the '96-'97 Fireblade.

Have a look at the '99 tank on my '95 945RR. The 93-95 frames were identical, so you can see how it looks:

http://i108.photobucket.com/albums/n19/simon-richards/profile8x6.jpg
http://i108.photobucket.com/albums/n19/simon-richards/frontside8x6.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tank2.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tank.jpg

bro sime, can you please stop posting the photos of ur bike ? its getting me impatient and jealous. :rant:

anyway looking on the bright side, i've already found a nice pair of 954 forks. due to receive em next month. will keep u posted about the progress and shall i run into any problems, i'll call SOS (sime) :D

sorry a little offtopic. :rolleyes:
 

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The aluminum plate is for the front of the 96-99 gas tank. It is to adapt the two hole new tank mount to the one hole mount your frame currently has.

sime can probably give you the dimensions and where to drill and tap the holes for the plate adapter. You should be able to pick up a piece of aluminum from a hardware store, if not ask at an aluminum supply seller.
 

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Dunc, it fits fine and looks great. It does require a small amount of fabrication (gotta make a small aluminium plate and drill/tap the frame - which is super easy), and you'll need to buy the mirror stay from the '96-'97 Fireblade.

Have a look at the '99 tank on my '95 945RR. The 93-95 frames were identical, so you can see how it looks:

http://i108.photobucket.com/albums/n19/simon-richards/profile8x6.jpg
http://i108.photobucket.com/albums/n19/simon-richards/frontside8x6.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tank2.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tank.jpg
Have you taken your Targa mirrors off, or are these older pics?

Cheers
Simon
 

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Hi guys. Sorry I've been away from this thread! I must have missed it.

Simon, they are older pics. I still do have the teardrop Targa mirrors on there.

Johan, I'm glad that you finally found some 954 forks! How is that coming along now?

To fit the 96-99 tank, I want to let you know that the mod you will do to your 93-95 frame will be irreversible!

Now let's get started...... you need to grind off the single post mount on the frame so that this section of the frame is completely flat. Then, take a flat piece of aluminum stock 5mm thick, by 1" wide x about 3.5" long. I don't know the exact length off the top of my head, but it is just a little bit narrower than the distance between the underside of the 96-99 front tank mount flange.

After sizing the plate, I used a Dremel sanding wheel to radius off the corners of the plate, then I used a lead pencil to mark the outline of the plate, making sure the plate was square and in line with the existing hole in the frame left over from the single hole mounting arrangement. I used the Dremel again to roughen up the underside of the plate, as well as the frame where the plate would go. I made sure the anodizing on the frame was removed in that part of the frame otherwise the JB Weld might not have adhered too well. But it is not critical as the bolts will tap through the plate and the frame which will lock it together. I erred on the safe side as I never wanted the plate to lift off!

I then used normal (not the 'Quik') JB-Weld to attach it to the frame, and waited overnight for it to dry. Next, I test fitted the tank (made sure the bottom mount under the seat was bolted in), put the mirror support and all the rubbers on too. When it was all centered, I used a metal punch to mark where the holes needed to be drilled. Removed all the hardware and drilled and tapped for an M6 thread. You have to take your time here to ensure that the hole is straight and perpendicular to the plate (don't just drill straight down from vertical!).

Test fitted it again including fitting the bolts till they were snug. Importantly, only use the factory steel bolts or equivalent stainless hex head bolts. Don't use those dressy anodized aluminum hex head bolts. They are not strong enough and will break off.

The next step is optional. When I was satisfied with the fit, I removed everything once more. I then took some JB Weld and with my fingertip, ran a bead around the plate and smoothed it into the frame. As I was powdercoating my frame, and JB Weld is fine for powdercoating, this made the plate look like it was a part of the headstem casting.

And there you have it. By the way, if you are going to retain your 93-95 gas petcock and fuel pump arrangement, you will also need to cut down the plastic fuel strainer. This is because the 96-99 tank is not as tall as the 93-95 tank. The strainer is a compression fit once you cut it down.

Pics attached:

http://i108.photobucket.com/albums/n19/simon-richards/Tankmount1.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tankmount2.jpg
http://i108.photobucket.com/albums/n19/simon-richards/tankmount3.jpg
 

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alright so I have to ask Sime, are you an engineer or what, cause you come up with some pretty cool ideas that most average guys wouldn't think of
 

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alright so I have to ask Sime, are you an engineer or what, cause you come up with some pretty cool ideas that most average guys wouldn't think of
Thanks!

The answer is no.... I'm just a cheap bastard!!!!:rotfl:

They say that necessity is the mother of all invention. When I moved back to Australia, I wanted to bring a new or near new 2004 ZX10 with me, but you need to have owned the bike for at least 12 months continuously before you can bring it into Australia as a personal import. Well, in 2004, I didn't have the money for a new (or even used) ZX10, so I had no choice but to import my 1995 900RR, because that's what I had owned for over 12 months.

So, given that I owned this bike and couldn't afford AUD$18000 to buy a new ZX10 in Australia (about USD$15000), I got stuck into rebuilding my bike so that it could compete with the newer bikes. Along the way, I just tried different things. Some things worked and some didn't.

Everything I have done is all self taught. And it's been that way because I couldn't afford to pay somebody else to do it. I haven't taken any mechanical courses. I just like to research and read, ask questions and try stuff. I guess my biggest fear is/was having a bike that looked like everybody elses and/or doing things half-baked where things just don't look 'right' - if you know what I mean. That's why I put so much effort into making my bike look the way it does - and the reason why I re-did the Camel decals twice. I wanted it to stand out and look the goods! I wanted it to look as 'correct' as possible.

I guess I'm kind of a McGuyver by financial necessity! :thumb:

Cheers,
Sime :)
 

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I guess I'm kind of a McGuyver by financial necessity! :thumb:

Cheers,
Sime :)
You sound like it.....why are the bikes so much more expensive over there? and whats the deal with the 12 mth period, thats kinda odd if you ask me, but not everything or everyone in this world is rational....
 

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I guess it's got to do with economies of scale, and our tax structure. We don't import anywhere near what North America consumes in motorcycles, so the per unit cost is going to be higher.

As to the 12 month period, I guess it's because they don't want a flood of much cheaper privately imported vehicles in the country. It only costs about $1500 to freight a bike from the US to Australia, so if you can get a 1000RR new for about $8.5-$9K in the states, it would be cheaper to buy it OS and being it in yourself....as opposed to buying to from a dealer locally over here.

So they make it hard to do. And only people that have lived OS and owned the vehicle for a 12 month continuous period are permitted to privately import vehicles.....and we can only import one during each 12 month period.
 
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