Announcement

Collapse
No announcement yet.

1981 Kawasaki KZ750 Resurrection

Collapse
X
 
  • Filter
  • Time
  • Show
Clear All
new posts

    Originally posted by Nessism View Post
    Hi Dale,

    The fault was mine; the bearing shown in the photo (sticking up too high) belongs on the steering stem. I mixed up the upper and lower roller assembly. The proper bearing is lower profile than the bearing shown.

    I just ordered the OEM Kawasaki upper bearing because it comes with a seal attached. Also getting the OEM upper umbrella shield/seal. The lower All Ball's bearing should be okay, after I install the lower seal of course.
    No, I probably skimmed through the details.The downfall of my occupational situation at times. I keep getting interrupted.
    De-stinking Penelope http://thegsresources.com/_forum/sho...d.php?t=179245

    http://www.thegsresources.com/_forum...35#post1625535

    Comment


      Good work Ed. Wish I knew you wanted to fit GS1000 progressives. We could have figured something out on the set I have & then I could have got the Sonics for the GS1100 forks...

      Oh well...!

      Be good to see it when it's done
      1980 GS1000G - Sold
      1978 GS1000E - Finished!
      1980 GS550E - Fixed & given to a friend
      1983 GS750ES Special - Sold
      2009 KLR 650 - Sold - gone to TX!
      1982 GS1100G - Rebuilt and finished. - Sold
      2009 TE610 - Dual Sporting around dreaming of Dakar..... - FOR SALE!

      www.parasiticsanalytics.com

      TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

      Comment


        Originally posted by salty_monk View Post
        Good work Ed. Wish I knew you wanted to fit GS1000 progressives. We could have figured something out on the set I have & then I could have got the Sonics for the GS1100 forks...

        Oh well...!

        Be good to see it when it's done
        Hi Dan,

        Didn't know the two bikes share the same springs until going to order. Found a good deal on the springs or would have ordered Sonic springs as well.
        Ed

        To measure is to know.

        Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

        Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

        Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

        KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

        Comment


          Put new wires in the coils. Was able to pull the exterior protective shield tubing off the old wires and install them on the new wires. Installed new plug caps too. Went with NGK's from Z1. Not OEM but that's okay for this project.

          P1010603 by nessism, on Flickr

          P1010602 by nessism, on Flickr
          Last edited by Nessism; 07-30-2017, 07:18 PM.
          Ed

          To measure is to know.

          Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

          Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

          Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

          KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

          Comment


            Little more progress...

            Decided to clean up the stock shocks and use them until I decide what to do long term. Had an epic battle (very steep learning curve) with taking these things apart. The adjustable damping mechanism in particular. At any rate, got them sorted. Blasted and gunkoated the springs. Got a few chips during the install process. Bodies and chrome pieces were really pitted so couldn't get rid of all that. Oh well, they will do for now.

            Didn't install the rear brake because the hanger bracket looks like crap (corrosion pitting). Going to ebay a new one. Need a new brake pedal too. Painted the one I have black but want chrome. It's only money...

            P1010615 by nessism, on Flickr

            P1010616 by nessism, on Flickr

            P1010649 by nessism, on Flickr

            P1010644 by nessism, on Flickr

            P1010645 by nessism, on Flickr

            P1010646 by nessism, on Flickr
            Last edited by Nessism; 07-30-2017, 07:41 PM.
            Ed

            To measure is to know.

            Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

            Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

            Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

            KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

            Comment


              Wow!!!!! It's looking great
              Cowboy Up or Quit. - Run Free Lou and Rest in Peace

              1981 GS550T - My First
              1981 GS550L - My Eldest Daughter's - Now Sold
              2007 GSF1250SA Bandit - My touring bike

              Sit tall in the saddle Hold your head up high
              Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
              and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

              Comment


                Wow...so nice!

                Comment


                  All one has to do is look at the first pics to really appreciate how nice it all looks now. Amazing transformation. Well done.
                  1979 GS1000S,

                  1982 Honda CX500 Turbo, 1982 Honda MB5 w/CR80 motor, 1977 Honda "nekid" Goldwing, 1976 Honda CB550F cafe', 1972 Honda XL250 cafe'

                  Comment


                    Originally posted by nvr2old View Post
                    All one has to do is look at the first pics to really appreciate how nice it all looks now. Amazing transformation. Well done.
                    Good point............ incredible work, Ed.

                    Comment


                      Going to be a thing of beauty for sure.

                      Comment


                        Put the brake lines together today. Earl's Speed-Seal. Took some photos in anticipation of making a tutorial. We all know how much everyone likes photos around here...

                        Old lines...

                        P1010650 by nessism, on Flickr

                        P1010652 by nessism, on Flickr

                        New Earl's parts...

                        P1010654 by nessism, on Flickr

                        P1010657 by nessism, on Flickr

                        Tools...

                        P1010656 by nessism, on Flickr
                        Last edited by Nessism; 07-30-2017, 07:50 PM.
                        Ed

                        To measure is to know.

                        Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                        Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                        Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                        KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                        Comment


                          P1010660 by nessism, on Flickr

                          P1010663 by nessism, on Flickr

                          P1010664 by nessism, on Flickr

                          P1010666 by nessism, on Flickr

                          P1010667 by nessism, on Flickr

                          P1010695 by nessism, on Flickr


                          Look down inside the ferrule and make sure the inner teflon liner is fully seated down to the step inside the ferrule.

                          P1010698 by nessism, on Flickr
                          Last edited by Nessism; 07-30-2017, 07:56 PM.
                          Ed

                          To measure is to know.

                          Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                          Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                          Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                          KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                          Comment


                            P1010672 by nessism, on Flickr

                            P1010674 by nessism, on Flickr

                            P1010675 by nessism, on Flickr

                            Shove the hose on firmly while tightening the nut. Tighten almost all the way, but stop just short so the hose end can be clocked with the other.

                            P1010676 by nessism, on Flickr

                            P1010677 by nessism, on Flickr
                            Last edited by Nessism; 07-30-2017, 07:58 PM.
                            Ed

                            To measure is to know.

                            Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                            Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                            Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                            KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                            Comment


                              Whack the chisel with the mini sledge...

                              P1010678 by nessism, on Flickr

                              P1010679 by nessism, on Flickr

                              P1010701 by nessism, on Flickr

                              P1010702 by nessism, on Flickr

                              P1010704 by nessism, on Flickr



                              Install the other hose end and pay attention closely to the clocking position. I used non adjustable hose ends but they work out fine. You just need to be careful to stop a little short of fully tight so you can get the clocking right.

                              P1010688 by nessism, on Flickr

                              Repeat everything three more times and...
                              Some heat shrink tubing can be used to cover up where the vinyl coating was removed. Next time...

                              P1010705 by nessism, on Flickr

                              P1010706 by nessism, on Flickr
                              Last edited by Nessism; 07-30-2017, 08:08 PM.
                              Ed

                              To measure is to know.

                              Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                              Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                              Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                              KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                              Comment


                                Originally posted by Nessism View Post
                                Little more progress...

                                Decided to clean up the stock shocks and use them until I decide what to do long term. Had an epic battle (very steep learning curve) with taking these things apart. The adjustable damping mechanism in particular. Removed the adjuster knob only to then realized the only way to install the detent balls and springs was by first drilling out four pins that hold them in place. Then I couldn't figure out how the damping feature worked; thought it related to rotating a rod down the main shaft, but it's related to pulling the rod up. At any rate, got them sorted. Blasted and gunkoated the springs. Got a few chips during the install process. Bodies and chrome pieces were really pitted so couldn't get rid of all that. Oh well, they will do for now.

                                Didn't install the rear brake because the hanger bracket looks like crap (corrosion pitting). Going to ebay a new one. Need a new brake pedal too. Painted the one I have black but want chrome. It's only money...







                                Hey Ed

                                Is the dampening changed by rotating the chrome shock cap?

                                I'm looking at rebuilding the stock set I got for my GPz

                                Did you take any pictures?
                                1978 GS 1000 (since new)
                                1979 GS 1000 (The Fridge, superbike replica project)
                                1978 GS 1000 (parts)
                                1981 GS 850 (anyone want a project?)
                                1981 GPZ 550 (backroad screamer)
                                1970 450 Mk IIID (THUMP!)
                                2007 DRz 400S
                                1999 ATK 490ES
                                1994 DR 350SES

                                Comment

                                Working...
                                X