Author Topic: Terry's Kawasaki ZZR1100 "Bring it back to life" project. (Read 74965 times)

RAFster122s · « **Reply #450 on:** July 21, 2019, 10:40:30 AM »

Why would you wait until after registration to change a bike's color?
David

spotty · « **Reply #451 on:** July 21, 2019, 05:58:59 PM »

our regulatory and inspectory bodies tend to appreciate things like they came from the factory and will look with a dim view to something as silly as a zebra stripe paint job

the problem then becomes if you paint it after rego you have to inform them of the change, hence the vmax has a full set of spare body work so if i get pinged with a stupid paint job i can just go home and put the stock stuff back on

so i might end up collecting a full set of zzr bodywork ( which is a hell of a lot more pieces than a vmax) so i can go silly with less worries

i had a look on the classifieds this weekend and i could pick up a complete bike with dead motor for $1K which would probably work out cheaper than buying individual pieces, there was also another ad for a chassis with good motor and electrics for $400, these things are cheap these days

Terry in Australia · « **Reply #452 on:** July 22, 2019, 12:09:41 AM »

Good idea Spotty, if you can find one with better bodywork but a dead engine, you might be able to keep the best original stuff for when they eventually become collectable (Don't laugh, even Yamaha's unfortunate TX750's are worth good money now, because so many went to God early in life) and you can display your manic side on the less than perfect panels.

I'm gutted that the folks at the local BWS have never heard of Ginger Joe. I burst into tears and was inconsolable until the nice lady gave me a 4 pack of Jim Beam Black and Cola as a consolation prize, (and to keep the line moving, the bottle shops are very busy here in Darwin) so I'm missing Melbourne more than usual, but hey, only 3 more sleeps before I'm back to freezing my tits off while working on my old swamp rat, while sipping on my favourite brew.

RAFster122s · « **Reply #453 on:** July 22, 2019, 12:38:50 AM »

If ya got the space you could pick up one or both. Just inspect the dead motor bike's plastics well before plunking down your cash...
How is the VMax's Corbin seat Spotty?

Terry, sorry you could not find your ginger beer or a good substitute.

David

Terry in Australia · « **Reply #454 on:** July 22, 2019, 12:47:33 AM »

Thanks David, it's 5.45 pm and I've just had my first cup of coffee for the day, but once it's done I'll crack a can of Jim Beam to accompany my cheese platter supper, and hopefully I'll have a great night's sleep tonight.

spotty · « **Reply #455 on:** July 22, 2019, 03:18:06 AM »

Finally got the forks apart today, what a fcukaround, but apart so that's the important thing
Give them a rinse and new seals and back in the bike , new wheel bearings should be here before the weekend so hopefully it'll all be back together by this weekend
Then the back end comes apart for wheel bearings, check the shock for level of fcukedness and linkages for the same, paint the swingarm, grease everything
One thing I have noticed on this bike is nothing that pivots or spins seems to have ever been greased but at least there haven't been any stripped or chewed bolts yet, probably cos the original owner never actually undid any of them

spotty · « **Reply #456 on:** July 22, 2019, 03:22:38 AM »

More forking bits awaiting their return to the darkness.
Also the front springs are the stock non progressive ones so that's something else to look for

Terry in Australia · « **Reply #457 on:** July 23, 2019, 03:43:26 AM »

I'm continuously impressed with the level of thoroughness you're putting into this build Spotty, well done mate, once I had the engine back together my only plan was to replace the fork seals and flush through the manky old brake fluid, and then do some skids. Unlike me, you probably won't kill yourself, or the bike. Good job.

spotty · « **Reply #458 on:** July 23, 2019, 08:01:39 PM »

well the way i'm looking at it is i'll do whatever i can within my capabilities and its just like a big model kit, part a joins to part b etc so how hard can it be...

and if i'm going to ride it i should actually check the stuff that might go wrong and get it looking as good as i can within my limited budget, i won't cop near as much sh1t as i normally do for riding some manky looking heap, that whilst it might be safe, looks like a heap

and if i finish it and a) it doesn't fit b) i don't actually like it (unlikely) c) it scares the crap out of me ( again, unlikely but possible)....then the better it looks the better chance i've got of getting a good price for it

and when its up and going the vmax gets a good clean up cos it truly deserves one after all the years i've owned it ( see manky looking heap comment above)

RAFster122s · « **Reply #459 on:** July 23, 2019, 11:06:59 PM »

How hard or feasible would it be to touch up the frame paint assembled as it is? It looks a little worn through in many places. Would imagine with masking it could be sprayed on the outer surfaces while the fairing is off. If you could match the sheen and color of black....

spotty · « **Reply #460 on:** July 23, 2019, 11:15:55 PM »

most of the frame scratches are covered by ( and i'd say caused by) the fairing, so it shouldn't be too much of a problem

i'm reluctant to start touching up the frame as i don't know whether i could match the paint without doing a full respray

all the stuff i'm doing as i go i'm completely painting so even if it doesn't match the original at least its all one colour ( or shade as the case may be)

PeWe · « **Reply #461 on:** July 24, 2019, 02:55:11 AM »

Terry did not leave any Rust-oleum with the bike?
Something like this

spotty · « **Reply #462 on:** July 24, 2019, 03:24:31 AM »

Started putting the forks back together tonight and....
one of them has gouges at exactly where they sit against the seals wiwth the forks fully extended so my guess is someone tried to get the deal out without pulling the forks apart
Got the 2 part epoxy putty out, mixed up a small blob and whacked it on, smoothed it out and left it to set.get back to it tomorrow, sand it back and hopefully it will have filled the grooves
Got the other fork back together but no oil yet, I'll do that to both at the same time when I put them back in the bike
Got new bearings for the front wheel delivered today, while I was doing eBay feedback I noticed that I bought them from a pallet jack supplies shop..... while they might be up to 3mph with half a ton on them I'm not sure I trust them at 150mph with me on them
Got better ones coming later in the week
Ah well there are other things to be getting on with

spotty · « **Reply #463 on:** July 24, 2019, 03:27:43 AM »

More photos

You will note the bearings are labelled ' premium ' .....

spotty · « **Reply #464 on:** July 25, 2019, 03:04:45 AM »

Today's stuff

New tank Cap and green screen bolts, I have a certain tightening in the pants

spotty · « **Reply #465 on:** July 25, 2019, 03:13:31 AM »

Had planned to get onto the knackered fork keg tonight but by the time I had walked the dogs , got some beer into me and cooked dinner I"m stuffed
Tomorrow looking good and the weekend seems free ( so far ) so hopefully I can get it sorted and get the front end back together

In the meantime nay the beer be with you, and check these pads....racing thickness lightening or knackered, your choice

RAFster122s · « **Reply #466 on:** July 25, 2019, 06:27:10 AM »

The PPO spared no expense on maintenance and safety it is clear to see.

What are green screen bolts? What do they go to?

Don't let Mrs. Spotty catch you having tightening in the pants over your new parts...she might get jealous.

spotty · « **Reply #467 on:** July 25, 2019, 03:01:00 PM »

screen bolts hold the windscreen onto the top fairing, i think the stock ones were just black phillips head stuff so it needs some bling

Terry in Australia · « **Reply #468 on:** July 26, 2019, 01:58:49 AM »

Very Nice Spotty, it might be the remnants of the prostate surgery but there is no pants tightening at my end (so to speak) but whatever, new parts are always good. I think I'm gonna start a build thread for the K7 "Street Scrambler" because a couple of parts I decided I couldn't live without have come in, so even though it hasn't moved offa my trailer, and won't really get a look in until the warmer weather arrives, I might stray from my usual routine and do a "side build" to get it up and running sooner than originally intended. We'll see.

spotty · « **Reply #469 on:** July 28, 2019, 03:16:21 AM »

Well, some progress today

Finally got the second fork leg back together. Couldn't get the fork seal in until I borrowed a piece of poly pipe of correct dimensions which I used to belt the seal in, worked a treat and saved me $80 for the factory tool

Put the forks back in the triples

Heated the bearing seats up on the wheel and got the bearings in with a minimum of fuss, discs back on and wheel in the forks, spins beautifully

Undid the front brake lines at the bottom triple and stripped them down, they were filthy but came apart nice and easy...... except for getting the pistons out, what a fcuking pain in the arse
Lots of heat gun action and a firm grip on the pliers eventually got all 8 of the little bastards out
The pistons are well manky but should clean up ok, the dust seals are rooted but the inner ones look fine, might see what can be rescued but prob just as easy to replace the lot
The bodies are filthy but should clean up fine ( when Mrs spotty isn't home and the dishwasher needs using....)and the new lines are here
I knew the old pads were thin but wafer thin would not be overstating it, pretty much just a stain of brake material left on them except for where it's just metal.
That was as far as I got on the zzr, the VMAX needed starting for the first time in months, had the battery on charge last week so thankfully the fcuker started , helmet and gloves on and a brisk half hour ride dodging dickhead tourists and making sure that the battery was happy

spotty · « **Reply #470 on:** July 28, 2019, 03:23:36 AM »

Also forgot, the fork leg that was damaged, I tried bogging it up and sanding but all the big came out of the scratches, I ended up getting a ludicrously fine micro file and just dressing the edges until it was at least smooth
The damage is actually below the level of the fork seal at full extension so it should never actually be able to leak oil past the seal or damage it as there are no sharp edges now

spotty · « **Reply #471 on:** July 28, 2019, 03:28:37 AM »

More pics

spotty · « **Reply #472 on:** July 28, 2019, 03:31:18 AM »

RAFster122s · « **Reply #473 on:** July 28, 2019, 05:23:55 AM »

Nice progress Spotty. I always reach for the grease gun for reluctant pistons, it works well and is easy.

Gotta hop in and out of the shower before I gear up to ride to church. Going to be about 68-70f for ride there and close to 80-84 for ride back home few hours later...

Might as well pony up for new caliper seal kit as good brakes help keep you alive.

spotty · « **Reply #474 on:** July 30, 2019, 11:22:00 PM »

just got a price on tyres, shinko 010 apex, $300 fitted if i take the wheels into the shop, seems like a bargain and without the motor in the bike it shouldn't be a problem getting both out at the same time

https://www.ebay.com.au/itm/Shinko-010-Apex-Radial-Rear-Tire-Sold-Each-180-55ZR-17-XF87-4073/392360162302?epid=171104831&hash=item5b5a7cf3fe:g:4~kAAOSwWz1dPr54&frcectupt=true

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Author Topic: Terry's Kawasaki ZZR1100 "Bring it back to life" project. (Read 74965 times)