1981 Kawasaki KZ750 Resurrection

[rustybronco]

Hi Dale,

The fault was mine; the bearing shown in the photo (sticking up too high) belongs on the steering stem. I mixed up the upper and lower roller assembly. The proper bearing is lower profile than the bearing shown.

I just ordered the OEM Kawasaki upper bearing because it comes with a seal attached. Also getting the OEM upper umbrella shield/seal. The lower All Ball's bearing should be okay, after I install the lower seal of course.

No, I probably skimmed through the details.The downfall of my occupational situation at times. I keep getting interrupted.

[salty_monk]

Good work Ed. Wish I knew you wanted to fit GS1000 progressives. We could have figured something out on the set I have & then I could have got the Sonics for the GS1100 forks...

Oh well...!

Be good to see it when it's done

[Nessism]

Good work Ed. Wish I knew you wanted to fit GS1000 progressives. We could have figured something out on the set I have & then I could have got the Sonics for the GS1100 forks...

Oh well...!

Be good to see it when it's done

Hi Dan,

Didn't know the two bikes share the same springs until going to order. Found a good deal on the springs or would have ordered Sonic springs as well.

[Nessism]

Put new wires in the coils. Was able to pull the exterior protective shield tubing off the old wires and install them on the new wires. Installed new plug caps too. Went with NGK's from Z1. Not OEM but that's okay for this project.

P1010603 by nessism, on Flickr

P1010602 by nessism, on Flickr

[Nessism]

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. 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...

P1010615 by nessism, on Flickr

P1010616 by nessism, on Flickr

P1010649 by nessism, on Flickr

P1010644 by nessism, on Flickr

P1010645 by nessism, on Flickr

P1010646 by nessism, on Flickr

[cowboyup3371]

Wow!!!!! It's looking great

[jwhelan65]

Wow...so nice!

[nvr2old]

All one has to do is look at the first pics to really appreciate how nice it all looks now. Amazing transformation. Well done.

[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.

[SVSooke]

Going to be a thing of beauty for sure.

[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

[Nessism]

P1010660 by nessism, on Flickr

P1010663 by nessism, on Flickr

P1010664 by nessism, on Flickr

P1010666 by nessism, on Flickr

P1010667 by nessism, on Flickr

P1010695 by nessism, on Flickr


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]

P1010672 by nessism, on Flickr

P1010674 by nessism, on Flickr

P1010675 by nessism, on Flickr

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.

P1010676 by nessism, on Flickr

P1010677 by nessism, on Flickr

[Nessism]

Whack the chisel with the mini sledge...

P1010678 by nessism, on Flickr

P1010679 by nessism, on Flickr

P1010701 by nessism, on Flickr

P1010702 by nessism, on Flickr

P1010704 by nessism, on Flickr



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...

P1010705 by nessism, on Flickr

P1010706 by nessism, on Flickr

[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?