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Endurance racing the brand new ZX4R

  1. #1
    Soul Rider Paul_E_D's Avatar
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    Endurance racing the brand new ZX4R

    Hey race fans, you didn't think I was taking the whole winter off, did you? Nah. When Billy Saine asked if we wanted to do some crazy Ceparano Endurance Classic at jennings gp, we said yes, what's that? 3 races totaling 11 hours at a track we have yet to ride, both directions on a brand new Kawi zx4rr. Hell yeah! Billy, Kerry Smith , Semir Faz and myself committed to the project.

    Friday practice got off to a damp start but the weather just kept improving and we all got laps in on both the sv and the 4rr in both directions.

    First impressions of the track were, fast and flowing followed by a series of tight corners and short straights finishing with 2 more fast corners. Abrasive and grippy pavement. Fun.

    First impressions of the 4rr: basically a comfy, heavier 125gp bike. It rails corners, brakes incredibly well with DPBrake pads, and accelerates surpringly hard if you keep it screaming between 12 and 14k rpms. It did have 2 flaws: a sloppy gearbox and a tendency to chatter badly while trail braking hard. But overall it had everyone smiling from ear to ear.

    Before we knew it race 1 was on. They did an F1 style rolling start, which was interesting. I had the first stint, so I set out hot and took the holeshot leading out the first lap. After a few laps, a red flag came out, so we lined up for a second F1 start. I battled with the leaders for most of the session despite struggling with gear changes.

    I handed the bike off to Kerry after 25 minutes and she headed out and got into a rhythm only to surprise us pitting in early running out of fuel. Whoops! We burned so much more in race conditions that we couldn't go the planned distance. We fueled the bike and sent her back out revising our strategy.

    Billy did his stint, then Sam but the tire was clearly not going to go the distance. I had over cooked it early on.

    Tire swap done we finished out the first race 4th in class.

    A quick lunch and it was time for race 2 in reverse direction. The track does not flow as well in this direction and the whole back section becomes stop n go. I think it penalized the 4rr more than the other bikes due to it's lack of torque and a severe chatter when trying to trail brake deep and hard.

    Billy lined up for the start of this one. The bike was already struggling to change gears, especially 3rd to 4th and 4th to 5th. Pretty much the gears we needed but we soldiered on.

    Semir took stint 2 and also struggled with shifting gears. I Went next, followed by Kerry.

    We all struggled with chatter and shifting woes, but we had a better fueling strategy and we made 1 tire go the whole way, finishing an improved 2nd in class.

    Sunday dawned cool and breezy, but full sun. A single 5 hour race was on the docket. By this time the gearbox was really giving us fits but we thought 2 rear tires would definitely go the distance.

    Billy Saine lined up for the rolling start. He crossed the line in 4th on lap one but immediately found a grinding false neutral in the fastest corner and ran off track only to re enter in last. Doh!

    He recovered and we soldiered on. The sound of the screamer pegging the Rev limiter could be heard from all sections of the track as we wrestled it through the gears.

    We made it halfway on the first tire so we confidently slotted a fresh one on and I went out hot to recover some ground. I ran a solid pace with a fastest lap of 1:23.6 and a long string of low 24s despite very slow and deliberate gear changes. The bike was on rails.

    Kerry, Billy and Sam ran solid stints all while testing the Rev limiter over and over.

    When Billy passed the bike to me for the last stint, all he said was, “the tire is just starting to get squirrely” OK, I'm thinking I can bring her home easily running around 1:30. My first few laps were at the 31 mark and the little 400 was spinning it up like a Superbike in the rain!

    Determined to hold my pace, I rode on my feet the whole time as the bike skated across the track both on entry and exit. I was getting lapped by the fast teams who had done multiple tire swaps, fronts included. It felt dangerous but the race was almost over and we didn't have any more tires to swap anyway.

    The front was now smoked too, and I was sliding both ends. I nearly highsided in turns 1, 2, 6, 11 on quite a few occasions. My pace slowed to 32, then 33 when I FINALLY saw the 1 minute board. My stomach was in knots, but I was going to make it. I actually thought, they are never going to believe me when I describe this. I took the checkers 3rd in class and the next thing I heard was Billy saying, “holy shit! Look at that tire!”

    I have to say a huge thanks to Billy for inviting us to ride the special bike. He put so much into this. We didn't baby it, but we didn't destroy it either!

    Thanks also go to DPBrakes, MTAGPIRELLI, as well as Mark Tenn pirelli and Tom Ceparano for making this happen!

    And finally to my teammates, Kerry Smith, Billy Saine and Semir Fazlic for all the hard work, fast riding, and big laughs

    Endurance racing makes for good friendships!

    Endurance racing the brand new ZX4R-20240128_105446-jpg

    Attached Thumbnails Attached Thumbnails Endurance racing the brand new ZX4R-shagged-jpg  

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    Paul_E_D


  2. #2
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    Why do the photos on this site suck?! I have forgotten how to use them I guess.
    But here's a cool Vid Billy made.


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    Last edited by Paul_E_D; 03-08-24 at 08:03 PM.
    Paul_E_D


  3. #3
    Kosher Assassin Stoneman's Avatar
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    Re: Endurance racing the brand new ZX4R

    Awesome report as always Paul! But holy FAHK, that tire!!!

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    Did you grit your teeth and try to look like Clint Fuckin' Eastwood?
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  4. #4
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    Quote Originally Posted by Stoneman View Post
    Awesome report as always Paul! But holy FAHK, that tire!!!
    Ha! Yesh. We had smoked a lot of tires over the 3 days. None looked all that bad, so I was out there thinking, they're never going to believe me when I say how tough it was to even finish the race on this thing. But the first thing I heard when I got to the pits was Billy yelling, holy shit look at that tire!

    My stomach was in knots from the stress of trying to keep decent times and not crash in every corner.

    Sent from my SM-S901U using Tapatalk

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  5. #5
    Lifer Kurlon's Avatar
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    Re: Endurance racing the brand new ZX4R

    My FZR would eat tires quicker than similar power SVs too, it was comical how fast it'd lunch an SC0 when they were testing that in a 160. They're small bikes but the screamer four cylinder never lets that rear tire get any rest vs the lumpy output of a twin.

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  6. #6

    Re: Endurance racing the brand new ZX4R

    That tire is smoked surprising it still held air; I am sure the front looks as bad. You're the man for keeping it up right and finishing.

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  7. #7
    Your Father csmutty's Avatar
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    Re: Endurance racing the brand new ZX4R

    Great read Paul! That tire is smoked! Why do you think sections came off like that instead of the whole circumference being worn down in that area?

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  8. #8
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    Hot spots? That is just the way they come apart.

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  9. #9
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    Quote Originally Posted by MUZ720 View Post
    That tire is smoked surprising it still held air; I am sure the front looks as bad. You're the man for keeping it up right and finishing.
    Agreed, it had worn through the steel belts in spots. That's getting deep into the carcass. I suspect it was about to pop. I was still knee down in all corners, but on the left side it took all my brain power to overcome my instinct NOT to lean over that far. I'm surprised I stayed up, but the bike was brand new and it's Billy's baby, so I willed it to stay on the wheels.

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  10. #10

    Re: Endurance racing the brand new ZX4R

    but the bike was brand new and it's Billy's baby,
    Billy will look at that tire and say I can still do 19s at Loudon with it. lol

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  11. #11
    Lifer nt650hawk's Avatar
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    Re: Endurance racing the brand new ZX4R

    GREAT STUFF!!!!!!

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    Gino
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  12. #12
    no can kneedown feralchimp's Avatar
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    Re: Endurance racing the brand new ZX4R

    Awesome read, Paul.

    Surprised by the gearbox issues; my first impression was that it's an outstanding little clickah. Maybe the difference between "me on the street" and "y'all on the track"? Any ideas for making it more resilient to the kinds of load you're putting on it?

    Love the grips and wheels; who did the paint?

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    -Jared
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  13. #13
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    I would say it was possibly our fault for setting up the linkage wrong and using an aftermarket QS, except that Kawi's are know for 2 issues: soft gearboxes and chatter. Since those are the 2 things we struggled with, I'm going to say that the gearbox could use some work. Billy has had the cases split and polishing/undercutting done on the box. He's headed back to Jennings soon, so we will know more shortly. THe problem was definitely made worse by the fact that were were WFO for every shift, and trying to make them as quickly as possible. I was the only one able to lap quickly and not miss shifts. I was very slow and deliberate with my clutch and foot timing.

    A friend of Billy's in NH did the powder coating. I'll get the name. If you do it, you must get the matching Crocs. That's the rule.

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  14. #14
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    Scott at RACE Metalsmiths Machine Shop and Powder Coating(802) 295-7800 https://g.co/kgs/5ecRVNg



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    Paul_E_D


  15. #15
    Senior Member ducatirdr's Avatar
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    Re: Endurance racing the brand new ZX4R

    I noticed my stock QS acting weird with only a few hundred miles on the bike. I think it could be my foot not allowing a full return of the lever before trying the next shift. It was flawless at first. I hope its not something that ages poorly.

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  16. #16
    Lifer Kurlon's Avatar
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    Re: Endurance racing the brand new ZX4R

    I have that issue on my Pan Am, if I try to get quick I also get lazy and don’t let the lever fully return, shifter says no. Worse, I have a bad habit of preloading the shifter in anticipation of a shift which also causes a motor cut…

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  17. #17
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    We are getting ready to hit the road for the Ceparano classic again this year. Riding the same 400RR again with a spare motor in it. We will see how this one holds up. A few guys have had much better luck with the gearboxes than we did, so hopefully that one was a fluke. We will skip the blipper altogether, and possibly even the quickshifter. I'm looking forward to spending a little time doing setup work of the Friday now that I know the bike a bit. Tim Hogan of Superbike Services 44 is going to help us via zoom. We have a quickfill tank this time and a few other goodies. The bike is BRIGHT pink this year. They will see our glow before we pass them.

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  18. #18
    WMC original sdog30's Avatar
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    Re: Endurance racing the brand new ZX4R

    Quote Originally Posted by Paul_E_D View Post
    We are getting ready to hit the road for the Ceparano classic again this year. Riding the same 400RR again with a spare motor in it. We will see how this one holds up. A few guys have had much better luck with the gearboxes than we did, so hopefully that one was a fluke. We will skip the blipper altogether, and possibly even the quickshifter. I'm looking forward to spending a little time doing setup work of the Friday now that I know the bike a bit. Tim Hogan of Superbike Services 44 is going to help us via zoom. We have a quickfill tank this time and a few other goodies. The bike is BRIGHT pink this year. They will see our glow before we pass them.
    Awesome!

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  19. #19
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    Hey Race fans: Time for my Ceparano Endurance Classic write up. As usual, it was a roller coaster ride, so buckle up. (it's a long one)

    We drove down over 3 days in FRIGID weather, only to be greeted to GA/FL by 6 inches of snow! The roads were still frozen on the bridges but when we arrived at Jennings GP there were just a few remnants of snow in the shadows. The track was clear!

    This year’s line up featured:
    2023 Kawasaki 400RR
    Billy Saine
    Nick Leighton
    Kerry Smith
    And yours truly, Paul Duval

    If you followed last year, you know we had all kinds of bike problems including a failing gearbox and brutal chatter when trail braking. Our goals for Friday practice were to work through those issues. To resolve the gearbox Billy bought a spare motor and slotted that in. Shifting was drastically better. For the chatter, we had Tim Hogan Hogan of Superbike Services 44 on the line giving us some guidance. Every change we made was a step in the right direction until we had effectively eliminated the problem.

    We also spent time fitting a JUST finished endurance tank with quick fill built by Adam Kells AK Racefab and a captive rear wheel set up by Fast Frank. It took some practice to dial things in and try to estimate our new fuel capacity. We decided we could run 1 hour and 15 minutes at race pace between fuelings. It took 10 seconds to dump 4.5 gallons into the tank. SWEET! We also sorted a technique for front wheel swaps that allowed us to leave the brake calipers wired in place. This year’s strategy was to provide all riders with reasonably good tires instead of running to the steel belts like last year.

    I took the first race stint on Saturday morning. That involved a NASCAR style rolling start. I lined up in the front row, took the holeshot, and led out the first few laps. Alessandro DiMario came by on an SV and I held down second place for the remaining 45 minutes of my stint. The bike was working well and the sun was starting to work its magic on the cold track. I may have missed my team’s signals to come in 3 or so times… I passed the bike off to Billy, who rode a half hour, then we fueled and he passed to Kerry for her 30. When we started calling Kerry in, she indicated that the tire was done, so Nick got a fresh rear tire and finished with a strong 45 minute stint and we ended 2nd in class and 4 on the road for Race1

    With our fuel strategy confirmed and the realization that a rear tire wouldn’t last the 2.5 hours effectively, we set out in Race 2 (reverse course) with a well defined strategy. Kerry took the start and held down a strong 4th place overall, 2nd in class for 30 minutes. Nick took over for 45, then a full fuel and rear tire stop, and Billy took a 30, leaving me to finish with a good tire and a half load of fuel. I put my head down and rode almost sprint pace for the full 45. I reeled in team after team. I had just passed Ella Drehyer on the road when I lost focus in the high speed T14/13 area and BOOM, I was in the grass at 80+ MPH. I used the rear brake a loooong time until I could turn and point the bike back towards the track. I pinned it literally racing a couple of bike who were still on the pavement and merged back onto the tarmac. I had lost 12 seconds and had a lot of work to do all over again. I put my head back down and reeled in Ella and one other team before taking the checkers again 2nd in class and this time 3rd on the road!

    Our tire and fuel strategy paid off big time, as did our bike setup work. Everyone was riding well and we were looking forward to more improvements in Sunday’s 5 hour race in the CCW direction.

    It was Nick’s turn to start and he did a great job holding down second and even ending in 1st overall due to our pit strategy. Billy took over and rode a strong 30. We fueled and Kerry set off for 30. As we were readying the pit board to call her in, she did not come around. Uh-oh. We heard a bike was down, then the red flag came out. I watched as they cleared the scene in the distance. When they brought her in it was clear that she needed to go the hospital. I told the guys to soldier on without me and I started to break down camp so I could follow Kerry to the hospital in the motorhome.

    Billy and Nick got to work on the bike and got back in the race. They rode their hearts out in a marathon effort, both running personal bests and getting the stops done with a little assist from some volunteers. THey brought the bike home 2nd in class and 4th on the road again despite the incident!

    As the team captain, I couldn’t be more proud of this effort. I didn’t get to ride Sunday, but it didn’t matter. The remaining team picked up the slack and crushed the result. This is what makes endurance racing so much fun. Everyone gets their chance to shine. Mistakes are made, and efforts are redoubled until it is done.

    Massive thanks to Billy Saine for the amazing bike, hard prep work and gutsy rides. To Nick Leighton for the smart strategy inputs, bike setup help, and the absolutely herculean ride on Sunday taking both my 45s and his own 45s and dropping his times while he was at it. Also, both of you showing up at the hospital afterwards meant everything to Kerry and me. Thanks also go to Adam Kells of AK Racefab for dropping everything to build us a siiick tank, and Tim Hogan for being available on the line for set up work. Thanks also go to Mark Tenn of Pirelli for the great tire service, bike setup advice, and being there with Kerry. Chaplain Mark Merical was also there for us in a BIG way spending his time with us at the hospital, keeping things light, and generally being a great guy. And Tom Ceparano for all the hard work making this cool event happen!

    Pics:
    https://photos.app.goo.gl/ei8RrVi5s9m9sSKg9


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    Last edited by Paul_E_D; 02-05-25 at 10:29 AM.
    Paul_E_D


  20. #20
    Changes come butcher bergs's Avatar
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    Re: Endurance racing the brand new ZX4R

    Heal up, Kerry!!

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  21. #21
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R

    For the non FB crowd, Kerry lowsided hard and sustained 6 broken ribs, 3 displaced, and a hemo/pneumo-thorax (punctured lung). She spent 2 nights in the hospital in Valdosta, GA. She is a week out now, and starting to feel a bit better.

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  22. #22
    Lifer backinthesaddle's Avatar
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    Re: Endurance racing the brand new ZX4R

    ^^ Best wishes for a speedy recovery.

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  23. #23
    Your Father csmutty's Avatar
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    Re: Endurance racing the brand new ZX4R

    Oh man that was a great read but I hope Kerry feels better soon! Good thing she works out frequently or the injuries could have been worse!

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  24. #24
    Soul Rider Paul_E_D's Avatar
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    Re: Endurance racing the brand new ZX4R


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    Paul_E_D


  25. #25

    Re: Endurance racing the brand new ZX4R

    Sorry to hear about Kerry. Get well soon.

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