I've been riding a 1995 Kawasaki ZX9R until it was stolen from me in 2003. I sincerely hope all motorcycle thieves will get robbed theirselves for at least double the trouble they cause to others. After that I tried a few other bikes, even test drove a new ZX10R, but eventually I bought a ZX9R B1 again. Apart from a few minor modifications, the model didn't change from 1994 to 1997. Even after all these years, it's still a weapon on wheels with moreh power than you could possibly ever need. I't runs smooth in low ranges up to a deep raw roar at higher speeds. Although prices have come down to a few thousand euros for a used ZX9R, it's not a bike for inexperienced motorcyclists.
When the ZX9R B1 model was engineered, Kawasaki didn't give it Xenon headlights, LED blinking lights, LED tail lights and 'Angel Eyes' CCFL lights, nor did it come with a hugger, undertail, automatic chain lube system or a seriously loud horn. Today, those are all affordable aftermarket extras. A lot of bikers like to add a personal touch to their wheels. I'll try to explain how I put some of these on my motorcycle. It's was a lot of fun although it often took a lot of time to find the right materials and methods. That's why I put together this page with my experiences. And to show of my pimped ZX9R of course!
We'll start easy. LED turn signal lights or flashers are for sale on just about every street corner. Unfortunately, not all of them fit very well on a ZX9R (or on any other bike for that matter). If you live near a bike store, it's worth asking them if they have experience with LED flashers for your model. Ask them if they are sure they will fit nicely and if you can return them if not. The same counts for buying them online. Keep in mind that returning them is useless if the postage is high. Sometimes it's not a good idea to buy online from far away because even if you get a free new flasher, usually you have to return the broken one first.
Another thing to pay attention to, is how much power they use. More is better, because more powerful LED lights will give more light. Even powerful LEDs will only consume a fraction of the power that 'old fashioned' light bulbs use. In case of the ZX9R, each flasher light bulb uses 21 Watt (12 Volt). LEDs usually use one ± 1 Watt.
Because the flasher bi-metal mechanism is adjusted to this 21 Watt power usage per bulb, you will need to simulated a higher power usage in order to keep it working. You'll have to add a parallel 8 Ohm resistor for each bulb you replace with a LED blinker. Or add one 4 Ohm resistor per side when you replace two bulbs per side.
One of the more appealing custom body work adjustments is the replacement of the undertail. Or the undertray or under seat whatever you call the bodypart that's below the back subframe of your motorcycle. As of now, I'm still in the process of making one fit:
It's all about the money, honey! The ol' supply & demand rule: The older your motorcycle is and the lower the number of it being made in the first place, the less demand there will be for parts. Lesser demand means it's harder to make money producing and selling those parts. Basically, the more exotic your bike is, the harder it is to find parts for it. General type of parts that are made to wear out, like chains and tires won't be a problem to find at a reasonable price. Bike specific parts and especially custom parts like aftermarket bodyparts such as huggers and undertails can be a lot harder to get by.
Generally only two groups of material used for bodywork:
I found this polyester undertail on eBay for € 55 including postage. At that time I was glad I had finally found one for my 1994 ZX9R. However, it doesn't fit very nicely, as later I found out later, after I already had it painted.. My advice: If you can find and afford one, buy a PVC undertail with a brand name that is already in the right color. The chance that it will fit snugly is a lot better.
Painted bodyparts can be up to twice the price of unpainted versions. Having them painted by a professional spray painter however, probably will cost you even more money, not to mention time. Even if you are so lucky to have the skills and access to equipment, you'll have to buy paint that is custom mixed for your bike. For example, the white for the ZX9R is not just plain white, it's a little off. Also, you'll need to put on several evenly, thin layers and preferrably, a finishing layer. I had my brother do it, since he was in the middle of repainting the bodywork of a whole bike, but it was a real hassle and I would not do it this way again. In my humble opinion, a paint job is only worth it when you can't buy the part prepainted in the right color.
For some bikes there are bold-on undertails, but I have not been able to find them for the ZX9R B1. If it's a consolation to you: Hardly any undertail can be fitted without some grinding or drilling. In case of our ZX9R, I wanted to keep as much of the original undertail as possible, for stability and to keep the necessary parts, are placed on it, like the flasher module. I didn't have a tool that was suited for this. Eventually I bought a Dremel. It's tempting to buy a cheaper brand and if this is all you are going to use it for, that's fine. However, to get in every corner at all the angles I needed, I found that even a Dremel has it's caveats. I just couldn't get everywhere, despite the flexible axis I bought with it. A Dremel 575 angle attachment was the solution. IMHO, this should be a standard accessory. I'm afraid Dremel is the only one that manufactures it. So if you buy a Dremel look-a-like, you might want to pick one that is compatible with the 575 angle attachment, to keep your options open.
Here's a view from the top so you have an idea what I cut away with the Dremel. In the process, I had to bold off the rear footpegs, some metal clips that are used to attach luggage, the fuse box, another small black box and a cilinder that is part of the shock absorber system. Of couse those need to be put on again later.
If you have any additions or corrections to this how-to, please let me know, so I can adjust it accordingly.