1981 Kawasaki KZ750 Resurrection

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

[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

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.

[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.

[gmansyz]

Lines

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

[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.

[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]

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.

[Big T]

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?

[Nessism]

Whack the chisel with the mini sledge...

P1010678 by nessism, on Flickr

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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...

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[Nessism]

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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.

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[Nessism]

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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

[Nessism]

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

Going to be a thing of beauty for sure.

[Vmass]

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.