Author Topic: Terry's Kawasaki ZZR1100 "Bring it back to life" project. (Read 74969 times)

bear · « **Reply #425 on:** July 10, 2019, 07:12:32 PM »

Not mention you also offered that Mega cam to me some time ago.
I have plenty of cams that would suit an 836 and as far as I'm concerned what's mine is your's Uncle Tez.

Cheers,
Brian

Terry in Australia · « **Reply #426 on:** July 10, 2019, 08:46:42 PM »

Quote from: bear on July 10, 2019, 07:12:32 PM

Not mention you also offered that Mega cam to me some time ago.
I have plenty of cams that would suit an 836 and as far as I'm concerned what's mine is your's Uncle Tez.

Cheers,
Brian

Thanks Brian, you're the man! Send me your address and I'll put that cam in the mail mate. I just want a mild street cam that doesn't need to be dialled in or clearanced.

bear · « **Reply #427 on:** July 10, 2019, 09:22:01 PM »

Will do.
We had a bit of a scrounge in the container a couple of weeks ago and re greased all the cams we could find and put them in a box. I'll have a look through them on the weekend.

There is more than enough gear to assemble another Hy-Vo motor in there as well, so we intend to get it together and flog it off for some beer money.

Sold our A motor some time ago and got good money for it.
Our B motor will stay with the bike and get sold down the track.

Cheers,
Brian

spotty · « **Reply #428 on:** July 13, 2019, 03:33:54 AM »

Good day today even though I had to go to an 8yo birthday party, it was at lunchtime so I got to drink beer before lunch which would normally get me right in the brown sticky stuff with Mrs spotty but it was her nephew so that's the price of getting me to attend
Got dropped off at home as herself, the mother in law and the 3yo neice went out for the rest of the day
Just keeps getting better
Pulled the sticking back brake off the zzr, pulled it to pieces , cleaned and reassembled and...
It works
Happy and pleasantly surprised

spotty · « **Reply #429 on:** July 13, 2019, 03:40:21 AM »

Tomorrow hopefully will get the zzr off the bike lift, modify the lift so I can get the back wheel into the wheel clamp and get the front end out to do fork seals and fluid
Also check wheel and headstem bearings and paint the fork lowers
Check pads for wear and measure lines for replacement with braided
Clean front guard
If I get time start on repairing the fairings

spotty · « **Reply #430 on:** July 14, 2019, 03:20:35 AM »

Took a while to get going this morning but got the zzr off the lift and widened the wheel clamp to take the zzr rear wheel, added about 2 inches and it's all good for everything from the VMAX front wheel (120 ) to the zzr rear (180)

spotty · « **Reply #431 on:** July 14, 2019, 03:27:08 AM »

Got the front wheel out after penising around with the dumbarse design Kawasaki decided upon ( and the changed for the next one cos it's stupid)
Discs are within size ( 4.8 now, limit 4.5 ) but pads were racing thickness....
Bearings seem fine but it's only a $10ish cost to replace so will do it anyway

spotty · « **Reply #432 on:** July 14, 2019, 03:38:59 AM »

Got the forks out after battling with the tightest triple clamp bolts I've ever met
Tried to get the 10mm Allen bolts out of the bottom to pull them apart to change the seals but the insides just spun. No luck.
I was only using an allen key as I don't have an impact 10mm Allen socket but I've worked out how to bodge one so I might have another go during the week
I did find it doesn't have progressive springs so that's something to look for later

spotty · « **Reply #433 on:** July 14, 2019, 03:48:55 AM »

Last job before beer o'clock was clean up the damaged bodywork of all the crap and glue the PO ( not Terry I hasten to add) had used to try and repair a cracked seam where the lower attaches to the top fairing
As far as I could tell there was super glue ( thin brittle coating), two part epoxy ( thick hard chunks), and contact cement ( rubbery stretchy stuff)
Cleaned all that off and clamped the two edges back together and ran a bead of superglue down the crack
Waiting an hour or so to let that set properly ( superglue only sets instantly when the parts are misaligned.. experience has taught me this if nothing else)

RAFster122s · « **Reply #434 on:** July 14, 2019, 11:27:43 AM »

You know about the trick to stop cracks in plastic is to drill a small hole at the end of a crack. It relieves the stresses and prevents the crack from spreading further.

spotty · « **Reply #435 on:** July 14, 2019, 03:12:16 PM »

Quite right , I shall drill the hole tonight before I move on to stage 2

spotty · « **Reply #436 on:** July 15, 2019, 03:56:21 AM »

Stage two tonight

The crack was all nicely set after leaving for a day so cut some plasterboard mesh (drywall to the rest of you chaps) and have started supergluing it in place

Going to leave it again for a night and then two pack epoxy over the lot

That should sort the fcuker

spotty · « **Reply #437 on:** July 17, 2019, 03:37:31 AM »

Got the Araldite happening tonight, slathered it all over the fibreglass mesh and left it to set.
Put all the little ducts and stuff back on the two lowers
Called it a night and called for a beer

spotty · « **Reply #438 on:** July 17, 2019, 03:40:31 AM »

Fairing photo ( maybe two if the gods are smiling upon me)

Terry in Australia · « **Reply #439 on:** July 17, 2019, 01:16:11 PM »

Good work mste, I'm looking forward to the initial "firing up of the sleeping dragon ceremony", what does one wear to such an auspicious occasion?

spotty · « **Reply #440 on:** July 17, 2019, 04:11:57 PM »

magical underpants and beer goggles

Terry in Australia · « **Reply #441 on:** July 17, 2019, 11:13:29 PM »

I've got to warn anyone with allergies that my undies contain traces of nuts, but regardless I'll wear clean ones for the grand reveal and (tyre) smoking ceremony. My beer goggles are (sadly) a permanent fixture nowadays, but I only feel drunk now when I take them off.

spotty · « **Reply #442 on:** July 21, 2019, 02:13:41 AM »

Some success, some fail so an average day

Couldn't get theforks apart, turns out my rattle gun is the Fischer price model so take them to work tomorrow and use pro power
Would have taken a quick trip to Terry world to have a go with his electro rattler but he's swanning round the territory pretending to do essential govt business

spotty · « **Reply #443 on:** July 21, 2019, 02:17:03 AM »

Took the front pegs, mounts , gear pedal and brake pedal off, cleaned, polished, painted, greased and reassembled and....

Nothing went wrong

spotty · « **Reply #444 on:** July 21, 2019, 02:21:53 AM »

And so onto the front wheel

Tried the usual method of removing the wheel bearings.... screwdriver and big hammer

Nothing, so rang a mate who actually knows what he's doing,followed his advice and hey presto, bearings out
Turns out the trick is to heat the wheel around the bearings and use a squared off drift to catch the edge of the bearing then tap away
Who'd have think there was a proper way ?
Also took the discs off to get better access to the hub with heat

spotty · « **Reply #445 on:** July 21, 2019, 02:59:25 AM »

Wheels and discs go to work tomorrow for a good hot high pressure washing, wheels are manky, as are discs
Also the floating part of the discs doesn't float any more, the 'buttons' that connect the disc to the carrier fill up with Smeg and brake dust and stop floating so a good blasting should have them rattling like a pair of good'uns

spotty · « **Reply #446 on:** July 21, 2019, 03:06:34 AM »

Then the prickly question of colour rears its ugly head

At the moment the bike is pretty much black , the wheels are charcoal with polished edges
I've got green brake lines, screen bolts, new black levers with green adjusters and one or two minor things on the way so......

Do I paint the spokes and centre ridges of the wheels Kawasaki green ?

Bearing in mind that the whole bike may yet end up Kawasaki green or at the very least black/ acid green zebra stripes....

Terry in Australia · « **Reply #447 on:** July 21, 2019, 03:24:44 AM »

Ha ha, just when I was going to congratulate you for doing such a thorough job (much more thorough than I would have thought to do) you start talking about Kawasaki Green? Oh wait a minute, I want Ginger Beer, so YAY! What a good idea! YEAH! (burrrppp)

spotty · « **Reply #448 on:** July 21, 2019, 04:01:30 AM »

Well it's either Kawasaki's very fetching shade of snot or the orange they used on the modern Z9's and that's almost the colour of ginger beer

But for the moment you can relax , it'll stay black until at least it's through rego

The VMAX on the other hand will be very lucky to make it to summer without being painted some disturbing shade of loud
That's assuming the bloody thing decides to start, we've been having some issues in that department lately
Battery is on charge and hopefully we'll get a couple of dry days so I can get it out for a blast to work this week

spotty · « **Reply #449 on:** July 21, 2019, 04:04:52 AM »

In the meantime some shiny zzr bits

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Author Topic: Terry's Kawasaki ZZR1100 "Bring it back to life" project. (Read 74969 times)