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1981 Kawasaki KZ750 Resurrection

Really nice looking work Ed. Must be nice to have a talent for these kinds of jobs.. Keep up the good work.
I continue to look forward to your progress.
 
Talent? Not so sure about that. Just busting my a*s is all. And speaking of busting a*s...the steering head bearings kicked mine this afternoon. Getting the old bearing races out of the steering neck was a major pain because they don't stick out where you can get a drift or race remover on them. Wound up cutting a slot in them with a dremel and then using a chisel to crack them so they could be extracted. The upper was easy, but the lower is recessed into the neck so it was really hard to work in there. Got it eventually, but it took me a couple hours. Not fun.

Tried to install the new All Balls bearings but ran into trouble. For one thing the races pressed into place with only minimal force. Doesn't seem right but not sure. Put the lower bearing on the stem, and forgot the seal that was supposed to go down first.:mad: The stock bearings didn't have a seal like that so guess it's no big deal. The upper bearing sticks up quite tall so that seems wrong. Can't find my old bearing to compare though. Worst part is the lower triple is hitting the steering neck so know something is wrong for sure. Frustrating.

For the most part the Kawasaki parts fishe is really good, but they made a lot of changes on these bikes year over year and sometimes the fishe is wrong. For example, they show loose ball bearings but my bike had taper rollers. I'm pretty sure they are stock. At any rate, need to research this situation and figure out what's going on...

P1010582 by nessism, on Flickr
 
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Your KZ750E came with those stupid loose balls and races!!! Someone must have installed some aftermarket tapered roller bearings at one time. I had both '80 and a '81 E model, and both had those little ball bearings that spread all across your shop's floor when you pull the lower tree!!! The Kawasaki microfishe is correct.

I always used the aftermarket roller bearings that K&L Supply sold over the years in my bikes. Never had a problem like you are having with your bearings ever in the ones from K&L!!!
 
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Wester Cooley said:
Your KZ750E came with those stupid loose balls and races!!! Someone must have installed some aftermarket tapered roller bearings at one time. I had both '80 and a '81 E model, and both had those little ball bearings that spread all across your shop's floor when you pull the lower tree!!! The Kawasaki microfishe is correct.

I always used the aftermarket roller bearings that K&L Supply sold over the years in my bikes. Never had a problem like you are having with your bearings ever in the ones from K&L!!!
Click to expand...

Humm, okay then. Thanks for the info. That would explain a few things. The upper bearing top cap/shield piece is rounded shaped. Do I need to get the rectangular style from a GPz?
 
That looks like the lower bearing to me. It has that tall boss on the inner race.

Didn't you say the lower tree hits the steering neck after you installed the new bearing and race??

That boss would push your lower tree away from your steering neck if it was installed on your lower tree!!!

Its been like 30 years since I worked on a KZ750E model, so I might be wrong.
 
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Wester Cooley said:
That looks like the lower bearing to me. It has that tall boss on the inner race.

Didn't you say the lower tree hits the steering neck after you installed the new bearing and race??

That boss would push your lower tree away from your steering neck if it was installed on your lower tree!!!

Its been like 30 years since I worked on a KZ750E model, so I might be wrong.
Click to expand...

I do believe you're right WC! I sure made a mess of this one. Going to have to get another kit because the lower bearing is pressed onto the stem, and their ain't no way to get it off without destroying the bearing (with my existing tools that is).:(
 
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Been researching head bearings in an attempt to sort through this mess.

The later model bikes that came with taper roller bearings use a different upper bearing umbrella shield than the early loose ball head bearing bikes. Kawasaki's upper roller bearing part also has a rubber seal built in. The All Ball's kit comes with a shield/seal, but it won't do much good with the old umbrella part so I ordered the newer type this morning. I'm contemplating ordering the Kawasaki upper bearing too. After all this hassle, want this thing to seal properly.
 
Ed, I may be correct or I might be all wet, but to me, the picture you posted showing the upper bearing inserted in the neck looks like the bearing is riding higher than I consider to be correct. My gut tells me if the upper bearing/ race isn't an arm and a leg, spring for new ones.
 
rustybronco said:
Ed, I may be correct or I might be all wet, but to me, the picture you posted showing the upper bearing inserted in the neck looks like the bearing is riding higher than I consider to be correct. My gut tells me if the upper bearing/ race isn't an arm and a leg, spring for new ones.
Click to expand...

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.
 
Nessism said:
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.
Click to expand...
No, I probably skimmed through the details.The downfall of my occupational situation at times. I keep getting interrupted.;)
 
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 :)
 
salty_monk said:
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 :)
Click to expand...

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