1981 Kawasaki KZ750 Resurrection

[Nessism]

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?

Yup, top collar rotates. They are easy enough to take apart, just don't take the adjuster wheel thingie out of the top eyelet. Sorry, no photos.

[Vmass]

Thanks for the brake line tutorial!

I just received Suzuki OEM front brake lines (3) for a total cost of $168.00.

It's nice to have the original lines for aesthetics, but for reference purposes, what is the cost savings of making them yourself and how long does it take you to make 3 lines?

Thanks again, Ed!

[Nessism]

Thanks for the brake line tutorial!

I just received Suzuki OEM front brake lines (3) for a total cost of $168.00.

It's nice to have the original lines for aesthetics, but for reference purposes, what is the cost savings of making them yourself and how long does it take you to make 3 lines?

Thanks again, Ed!

Total was $89.61 for everything to make four lines + crush washers.

Given my druthers though, for a restoration like a 1000S, I'd go OEM instead.

The owner at AN Plumbing told me the screw together brake lines have a higher pull off force than the machine crimp type. Not sure if he's BS'ing me or what though. The store is local to me and they will make machine crimp lines for the same price as the bolt together, but after the owners comments, I've always gone bolt together.

[gmansyz]

Lines

How did you keep the braided hose ends from fuzzing up?
G

[Nessism]

How did you keep the braided hose ends from fuzzing up?
G

Hi Greg,
The stainless sheath will spread and fuzz up when you prep for the ferrule, but it's no worry. Just need to keep the fray down long enough to get the nut over the end.

[Wester Cooley]

Your step by step description on how to assemble braided steel lines is the best I have seen!!!

It shows its not some black art that only a few can accomplish in some hidden back room.

Anybody that views your postings should be able to assemble any type of braided steel lines.

The only thing I do different is I use a thin cut-off wheel in a die grinder to cut my hose.

[psyguy]

The owner at AN Plumbing told me the screw together brake lines have a higher pull off force than the machine crimp type. Not sure if he's BS'ing me or what though.

Interestingly, down here the "screw together" brake lines are illegal, apparently because they are not as reliable as the crimped type

[Flyboy]

Simply amazing Ed.
Another masterpiece in the making.
Kinda makes Jennifer look like a shade tree hack job.

[salty_monk]

Looking good

[srsupertrap]

Little more progress...

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...

Ed,
A couple of questions about the details shown in this photo. Did you buy new chain adjusters, hardware etc or did you opt to refinish the all the shiny hardware shown here? If you did refinished the hardware what is the process steps you used?

Second question, I have the same Tokico rear brake bracket shown. Any idea what the original color or finish was? Mine has a gold hue by the Tokico name then changes to black

TIA
Steve

[Nessism]

Ed,
A couple of questions about the details shown in this photo. Did you buy new chain adjusters, hardware etc or did you opt to refinish the all the shiny hardware shown here? If you did refinished the hardware what is the process steps you used?

Second question, I have the same Tokico rear brake bracket shown. Any idea what the original color or finish was? Mine has a gold hue by the Tokico name then changes to black

TIA
Steve

Hi Steve,

If you go back in this thread to post 175 there are details of how the parts were refinished. Basically, I stripped the old plating, polished the metal, then use a caswell's zinc plating kit to refresh the hardware.

Regarding the caliper hanger, I believe the finish as shown is correct - dark gray. I'm not happy with the amount of pitting in the metal on mine and bought a replacement off ebay, but when it arrived the front side is a lighter color and there is some spotting. Not happy with that one either so staying with the original. Reason I mention this is because I think the anodize fades or something. The 750 and 550 share the same part I believe, but finding a clean one can be a challenge. The guy I bought mine from refunded me, because I asked him specifically about the finish before buying and he said it's clean (which was wrong). At any rate, hope this helps...

[gmansyz]

Awesome job on the Hoses!!!!
Laters
G

[Nessism]

A little behind on the update...

Cleaned up the harness best I could and re-wrapped it with Elliott Tape EE 201 non adhesive tape. Good stuff. The 201 flavor is the high temp stuff so heat shouldn't be an issue. Non adhesive like the stock harness wrap so the harness doesn't turn into a sticky mess.

Used a combination of Deoxit, Scotchbrite, stainless steel wire brush, and a dremel tool to clean corrosion off the electrical contacts. Pinched closed the female terminals where ever possible.

Bought some new electrical terminals and crimping pliers from Vintage Connection. These things roll over the edges over on the terminals just like the OEM terminals. They seem more secure than the smash flat terminals that are so common these days.

Snuck in a SH-775 R/R under the battery box. Had to make a bracket first but it turned out pretty well.


Elliott Tape EE 201 by nessism, on Flickr

P1010643 by nessism, on Flickr

Crimping tool by nessism, on Flickr

[cowboyup3371]

Where did you find the tape Ed?

[jwhelan65]

Where did you find the tape Ed?

Wondering the same...