Topic: Terry's Kawasaki ZZR1100 "Bring it back to life" project.

[Terry in Australia]

Well I had intended to do some more on the big black beasty today, but I had my cortisone injection into my sore shoulder at 10:40, and as at time of writing, (4:30) it's still fcuking killing me, so no bike play. Good news though was that my new genuine Kawasaki cylinder sleeve arrived this morning from the US (thanks mate!) so I've now got everything I need to get the engine back together.

Last year I bought 3 Henry Abe CB750 wheels on Ebay for $375, but they won't pass a roadworthy inspection here in Victoria now as they're not OEM. (new laws) So  I put two of them back on Ebay on Monday, and yesterday a nice bloke from Japan bought them for $900 (AUD, $700 USD) plus shipping. Sweet, that'll pay for new tyres (Michelin Pilot Road 4) a roadworthy inspection, and my red "Club" plate, all that's standing between me and the road. (once I finish putting the engine together, of course)

Michelin Road Pilot 4 by terry prendergast, on Flickr

After I left the clinic I drove over to my local Bunnings Hardware store and bought some packing tape, and stole as many carboard cartons as I could to pack the wheels in.

Henry Abe to Japan 1 by terry prendergast, on Flickr

Henry Abe to Japan by terry prendergast, on Flickr

Henry Abe to Japan 2 by terry prendergast, on Flickr

I was a bit worried that I hadn't charged Hitoshi enough for shipping, but as it worked out, it was plenty, so I spent some more of his money on insurance. Hopefully they'll arrive in a week or so, and he'll send me a pic of them on his bike. More on the big black beasty's return to grace on the weekend. Cheers, Terry.

[spotty]

Terry, where did you get the info about OEM needed for RWC, just had a quick look at victoads and couldn't find anything about it, though I did see that pre74 bikes don't need a front brake light
I'm hoping my sympathetic rwc'er will allow a pass on some of the less original bits of the 750 trailbike when it comes time for that ( as it stands at the moment the only stock parts are the triple clamps....)

[Terry in Australia]

G'Day Spotty, Jeff at Ace Motorcycles told me he'd just done a mandatory 2 day course on all the new RWC regulations, he told me that the new rules state that if the exhaust, wheels, brakes etc are not OEM, they won't pass.

Also, frame mods, rechromed rims etc are a fail too. I asked him about old bikes that OEM parts are no longer available for and he said there is some leeway given to testers, but most of the POS Cafe bikes that have slipped under the radar in recent years are both the cause and the target of these new laws.

Have a look at my new Zed project that's been drag raced most of its life, it's gonna take a lot of work to get back on the road....... Have a chat to your friendly REC guy, he'll be able to expand on what Jeff told me.

[MoMo]

Seems like your govt. wants old bikes off the road ...Larry

[spotty]

i could be right in the poo here

[Terry in Australia]

You won't be on your own mate, these new laws were set up to sort out the hipsters riding around on dangerous home made POS', but the flow on effect is that it'll keep a lot of the good guys off the road, and modified bikes, no matter how well engineered, will be worth nothing......

[BPellerine]

You won't be on your own mate, these new laws were set up to sort out the hipsters riding around on dangerous home made POS', but the flow on effect is that it'll keep a lot of the good guys off the road, and modified bikes, no matter how well engineered, will be worth nothing......

and stock parts will go up in price as people try to get their bikes past testers,we cant build a chopper here and expect to drive it,but not yet to the point of running non stock wheels and exhaust.bill

[754]

Bill what about existing registered hardtails ? How about plunger frames?

[krusty]

As the RMS (DMV) NSW VJMC Registrar here in NSW I watched the sh1t that was going on, with those rogue red plate inspectors passing any POS, and what has happened was, to me not unexpected. At least in NSW we now have a modified category for 30+ year old bikes/vehicles with stringent inspection rules etc.
Minor mods are allowed for Historic (club) registration for non OEM replacement parts with like for like replacement. e.g. replacing handlebars, if the original was a one piece you could not replace it with clip-ons. We have leeway with unobtanium stuff like exhausts or safety upgrades like adding the extra front disc to a CB750.

[Terry in Australia]

There was a company here called Megacycle Engineering (no relation to the American company) that made custom exhaust systems for bikes, they worked very well and I had one hand built for my Suzuki GS1000S. When I went to collect my bike, I looked in their scrap metal skip bin, and it was full to the brim with almost new OEM exhaust systems for Gixxers, R1's, Harleys, Fire Blades, you name it.

At the time I wondered if, like the mighty CB750, in years to come, those unwanted OEM systems would be worth hanging on to? I almost wish I'd asked the proprietor if I could take home some of those pipes, I've got several bikes that I want to sell come summer, that have great aftermarket systems that probably won't make it past a Roadworthy inspection nowadays, so I'll have to see if I can find some OEM pipes going cheap on Ebay before the word gets out............

[BobbyR]

We have not yet fallen prey to that type of regulation in the US. Probably because other than the  federal basic requirements, roadworthy inspection is left up to the 50 States. We have a different set up here with State autonomy in some areas.

[BPellerine]

Bill what about existing registered hardtails ? How about plunger frames?

there are a few that have been grandfathered in and registered as antique,so no inspection needed for the life of ownership,but this does not transfer to a new owner,also insurance will give you a hard time unless you have a stock frame no,which aftermarket frames do not,plunger frame ok if had a if the bike came that way stock.bill

[spotty]

made enqueries last night, it seems our tame RWC'er will be exercising some latitude with regard to parts made of unobtanium ( pipes etc ) as well as casting a sympathetic eye on brake upgrades
it seems, as mentioned above, that the current crackdown is to stop absolute #$%*heaps hitting the road, one example that was mentioned was a front brake stay attached to the front guard instead of the forks.....
so i shall live in hope , the alternatives being i get trail reg or just put Vmax badges on the honda and swap the plate between bikes

[RAFster122s]

Glad you have managed to find some good deals to fix your bike.  You are on a kick to build/rebuild so keep it going and all the projects in the wings will get fixed and you will have even more bikes to choose from when riding if you can keep them insured and plated.  I think they  seize them here if you falsely put the plate of one on another, as tempting as that is...or can be...given fortunes to plate and insure them.

Glad you are mended, barring the shoulder...hope it heals up, mine havent. Oh, it is mononucleosis that I had.  It can kill you in a small percentage of instances but is often a mild case...I was trying to finish my senior spring term and wrap up my degree.  I took a hit in grades due to that rather than waiting a year to finish...

[Terry in Australia]

Thanks David, the shoulder is feeling better after that cortisone shot, it was interesting looking at the ultrasound screen as that big horse needle made it's way through the various muscle and tissue and finally landed in the Bursa, then watching the cortisone pumping into it. It hurt like a bastaard once the local anaesthetic that was mixed in with the cortisone wore off, but I think I'll sleep well tonight, as the shoulder feels better and my range of (pain free) movement has improved.

Ebay is a dangerous thing, I started to look at what I could buy for the ZZR with my Henry Abe money, and somehow ended up buying another bike! Oh well, it's another worthy contender, a 1977 Kawasaki Z1000 based drag bike that's fallen on hard times, so after I pick it up tomorrow (900 mile round trip) it'll get some love, once the ZZR is up and running. It's highly modified/slightly butchered and will need a lot of work and parts to get back on the road, but that's OK, working on bikes keeps me out of trouble. It's only when I'm riding them that things get a bit sketchy......

Terry's new Zed 3 by terry prendergast, on Flickr

[bill440cars]

      Welcome To Terry's Home For Wayward Bikes.   


     You know I am Joking with ya, Terry. Good that you can do that too.  Bill


    By the way, Always enjoy your posts, from the educational part, to your humor part. 

[PeWe]

The ZZR is soon up and running? You need to bore the new sleeve or enough to hone?
Your 1977 Kawasaki Z1000 buy have made me to check the old catalogs I have with tuning parts. A project bike would be nice.
RC388 or RC400 cams? Must have raw power from low to top!   Cam data look tame compared with CB750 cams.
Oil pump must be modified too, right? Plus the pan.

The Kawasaki Z1-900/1000 parts, new and old cost less than CB750 SOHC what I have seen so far!

Fun to check your build thread Terry. My wife like the bike restore pics when Leo is among them
My garage is small, a 3:rd bike will be noticed and there are plans to save money for a sunshine country apartment I do not want to argue against....

[754]

You need my RC angle mag drive, like new but no mag or dizzy..
 Speedy piece, but it's making me think of getting a Kawi to put it on.. or a display engine..

[RAFster122s]

Terry, glad you made out like a bandit on the Henry Abe's. I thought the Morris wheels has the single spoke,  T vs H shape.

Have fun with the two bikes!

Will the new cylinder liner need bored or honed to fit your piston? 

I have had a similar mobile feebay experience as you described.  I have sold things and a guy left neutral feedback because I pictured multiple items in a photo and clearly stated it was for a single item and I simply did the photo for convenience. He did not read the description or he would have known what he was buying and the listing title was singular. 

Hope your new drag bike can be returned to operation and on the road without spending too much.

David

[Terry in Australia]

Well what a day! I got up @ 0600 and was on the road at 0620, pitch black, cold, what was I thinking? Saturday mornings are for sleeping in! Anyhoo, the fuel gauge said I had 640 Kms (around 400 miles) before I had to stop for my first tankfull of diesel fuel, so once out on the highway I inserted my Deep Purple CD and warbled away to "Smoke on the water", My woman from Tokyo", and Speed King" and that set my mood for the drive ahead.

After refuelling and grabbing a coffee 400 miles up the road,  I drove for another hour or so, and arrived at Craigs place at 1215. It was pissing down rain, and I was in no hurry to load the bike, but that was OK because he wanted to start it for me and show me a few things first anyway. It was kind of sad actually, Craig has owned this bike for 30 years, he built it, he rode it on the street, and he drag raced it. Sadly he's got cancer and has decided to move to the Philippines to be with a girl he's been seeing, so he's just selling up everything, because he won't be coming back. 

The bike has been his pride and joy, and it fired up on the first kick. It sounds wicked, and has no rattles or clunks. There are some spares and stuff that I haven't even looked at yet, but I'll drag it out of the car in the morning and do an inventory. Man, I left home in darkness, and got home in darkness, but at least I'll sleep well tonight, and dream about big black Zed's lurking in my patio............ More tomorrow.

Terry's new Zed pickup day by terry prendergast, on Flickr

Terry's new Zed (Craig Alcock) by terry prendergast, on Flickr

[Stev-o]

Congrats on the new bike Terry, although that is a sad story of your mate.   At least he knows his bike went to a good home. 

Your becoming quite the Kaw Kid!   

[Terry in Australia]

Thanks Steve, it'll take a bit of work to put it back on the road, (lots of frame tabs have been chopped off, it's got a drum rear brake and not a disc etc) but I'm happy that the engine is good so I just have to do some fabricating and paint, but no oily bits.

I think this is only my third Kawasaki, I had my Z900 back in the 80's and sold it to buy my first Harley Sportster, then the prices for any Zed went thru the roof here, so I was lucky to find this one for so cheap, especially with the wicked engine mods. I've got to finish the ZZR first, then I can start to play with this one. Should be fun!

Terry's Zed Patio Stalker by terry prendergast, on Flickr

[spotty]

Or......does a zzr motor fit in a z frame

[RAFster122s]

 Widowmaker z1 framed zzr motor...wow, death wish

[Terry in Australia]

Ha ha, I think I'd be much safer putting the Z1000 engine into the ZZR, bullet proof old air cooled engine in a rigid chassis with great brakes and wide rubber, which is about the complete opposite of the alternative.......