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Classic Japanese MotorCycle Restoration
By Sid Young (AKA z900collector)
Restoration updates - April 2012
Small progress on a number of fronts over the last few months, the GPz900R is back on the road after I overhauled the cooling system. It now holds water, keeps cool and the new carburetor inlet rubbers removed all the misfiring issues. I have found a few cracks in the body work so I need to get some plastic welding done when I can afford it.
The GPz1100B2 is getting the engine Soda Blasted this week so that the paint and rubbish is removed prior to it being stripped down. I will be getting Wayne at Specialized Blasting Services to water blast the cases clean afterwards.
I have been trying to find time to build a new web site and completely focus it on restoration work but there is not enough hours in the day!
Some of my project work has been slowed due to finances and working on the house but this years plan of attack looks like being to finish the 1100 and find a new content management system for the web site.
Small progress on a number of fronts over the last few months, the GPz900R is back on the road after I overhauled the cooling system. It now holds water, keeps cool and the new carburetor inlet rubbers removed all the misfiring issues. I have found a few cracks in the body work so I need to get some plastic welding done when I can afford it.
The GPz1100B2 is getting the engine Soda Blasted this week so that the paint and rubbish is removed prior to it being stripped down. I will be getting Wayne at Specialized Blasting Services to water blast the cases clean afterwards.
I have been trying to find time to build a new web site and completely focus it on restoration work but there is not enough hours in the day!
Some of my project work has been slowed due to finances and working on the house but this years plan of attack looks like being to finish the 1100 and find a new content management system for the web site.
Site Map
Where would we be without the Internet!
I get a lot of email from fellow enthusiast on how to do various tasks from fixing wiring, changing swingarms to complete rebuilds! here is a typical request I thought I would share, if my book was finished I would sell them a copy!
I get a lot of email from fellow enthusiast on how to do various tasks from fixing wiring, changing swingarms to complete rebuilds! here is a typical request I thought I would share, if my book was finished I would sell them a copy!
On Sun, Aug 21, 2011 at 5:41 AM, <bdyfxr@aol.com> wrote:
Hi Sid,
I was doing some google searches and came across your site.. I have a 76 KZ 900 that I have owned since 1978, havent riden it since 1991 and now I want to restore it with lots of help or by a professional.
Looks like u may be in Austrailia?.. I am in California... Any direction you could point me in would be helpful.
Have a great day
KOS
Hi Sid,
I was doing some google searches and came across your site.. I have a 76 KZ 900 that I have owned since 1978, havent riden it since 1991 and now I want to restore it with lots of help or by a professional.
Looks like u may be in Austrailia?.. I am in California... Any direction you could point me in would be helpful.
Have a great day
KOS
I have reproduced my response, the significance occured to me when I picked up a GPz900R the other day as spare parts. It was "boxed" and when opened it appeared that every part had been disassembled!
Hi,
If you have never done a restoration before then I suggest you don't make the mistake that a lot of people make and that is to just strip everything down and end up with a box of bits. The better process might be to take one thing off and restore that piece, lets say you
start with the wheels, take the front wheel off, get the rim rechromed next get the hub water blasted clean, fit new bearings (from SKF or CBC or NSK - not cheap chinese bearings) and then get stainless spokes fitted, a new tyre and assemble back on the bike.
The bike is still complete but one item has now been done and should look great, then do the rear wheel the same way. Then rebuild the front end, next re-chrome the front and rear guard and perhaps the grab rail, get the seat recovered in the original pattern next. After that its instruments, switchgear and handlebar and controls.
At each step the bike is still complete, its starting to look good and you can then get it to a point where the frame, swingarm and
associated metal brackets can be powder coated or two-packed, the engine can be done first or last - its up to you.
The key thing is that when they are done, the rest of the bike is already done and the work is almost completed.
Do you see the pattern?
Have a good look at my web site http://z900.piczo.com/ I need to update some more content on my GPz1100 build, but there is tons of stuff on the z900.
As you progress, let me know and I can suggest the next step.
--
Sid
http://z900.piczo.com/
http://www.gpz900.org/
http://z900collector.wordpress.com
If you have never done a restoration before then I suggest you don't make the mistake that a lot of people make and that is to just strip everything down and end up with a box of bits. The better process might be to take one thing off and restore that piece, lets say you
start with the wheels, take the front wheel off, get the rim rechromed next get the hub water blasted clean, fit new bearings (from SKF or CBC or NSK - not cheap chinese bearings) and then get stainless spokes fitted, a new tyre and assemble back on the bike.
The bike is still complete but one item has now been done and should look great, then do the rear wheel the same way. Then rebuild the front end, next re-chrome the front and rear guard and perhaps the grab rail, get the seat recovered in the original pattern next. After that its instruments, switchgear and handlebar and controls.
At each step the bike is still complete, its starting to look good and you can then get it to a point where the frame, swingarm and
associated metal brackets can be powder coated or two-packed, the engine can be done first or last - its up to you.
The key thing is that when they are done, the rest of the bike is already done and the work is almost completed.
Do you see the pattern?
Have a good look at my web site http://z900.piczo.com/ I need to update some more content on my GPz1100 build, but there is tons of stuff on the z900.
As you progress, let me know and I can suggest the next step.
--
Sid
http://z900.piczo.com/
http://www.gpz900.org/
http://z900collector.wordpress.com
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1983 zx1100A1 Purchased for $1500 in Sydney, EFI Fault and lack of maintenance was quickly solved, eventually I will paint it and customize it slowly.
Latest News!
November 2011
Imbil rally!
Zephyr 550 serviced and returned back to Heather, now on hunt for a 550 or 750 for myself.
October 2011
GPz1100 forks at Hardchromers, ELR paint job on tank progressing. Now at frame assembly stage, machining new fasteners to fit GPz1100. Need new front tyre shortly!.
August 2011
Re-assembly of GPz1100 has begun, parts slowing being sent out for cleaning and others for powder coating, rear-end assembled to frame. Forks to go in next for hard chroming, then front end assembly scheduled. Tank spray puttied ready for sanding and first colour coat.
July 2011
Sent box of GPz1100 metal parts to get powder coated. Frame in getting done also. Bearings for swingarm arrived.
June 2011
Stripped GPz1100 and started to prep parts.
May 2011
GPz1100B2 Frame back from the engineers, work progressing slowly.
March 2011
Started to strip GPz900R, Alternator dead and Water pump leaking, new pump on the way. Needs strip and cleanup, a full service, 1 carby boot but otherwise OK.
Feb 2011
Final prep for WSBK 2011 ride.
October 2010
Sourcing parts for the GPz900.
Sourcing a cam chain tensioner for the z900 and head gasket to boot.
Started planning the rebuild of the GPz1100, wheels done!
August - September
z650 work.
GPz900R work
z900 Head rebuild
July 2010
Bearings arrived for z650, GPz1100B2 and GPz900R-A2
June 2010
Work on z650 wiring harness complete and installed - all OK!
Parts ordered for Hetaher's GPz900
WSBK2011 ride announced and organization started.
May 2010
30th - z650 Registered! More shiny parts ordered and some arrived.
Working like mad to get z650 roadworthy and reassembled.
April 2010
1977 z650B1 Stripped and sent to powder coater.
Parts for z900 arrived. GPz900R serviced and cleaned, oil change due this month.
March 2010
WSBK Gathering of the faithful 100% success!
z650 Stripped ready for powder coating.
GPz1100 serviced and carb Sync. GPz900R - Needs strip down and service.
February 2010
Prep for WSBK ride...
January 2010
Installed z900 wiring harness. Stripped z650 wiring and some body parts off.
December
Worked on z900 wiring harness, cylinder head cleaned. Soldered DFI system on GPz1100.
November
z900 engine install, DFI system on Gpz1100 to be soldered up and re-installed.
October
Tickets for super bikes, z900 engine assembly in good progress, z650 ready to register.
Z-Owners Maintenance day at my place.
September
Z900 engine rebuild coming along, zx1100 EFI serviced, z650 ready for rego and funeral for Dave Jones.
August 2009
zx1100-A1 EFI issues sorted, basic maintenance performed on bike. Test ride on deserted highway reaches 195 with no effort (with passenger holding on for deal life) and the power delivery is AWESOME! What a good score for $1500. z650 carbs synced and electrical issues corrected. Needs fork seals and front caliper stripped and cleaned.
Second zx1100A1 started first go and idles but restarts are an issue. More work needed
July 2009
z650 is running, test ride made up and down the street, exhaust leaking and may need fork seals. Otherwise all good! Updated web pages for z900A4 and z650.
June 2009
Update - Sold all Honda parts and the 750 cafe racer project as well as the z1000G.
Rode to Dalveen for the Granite Gnome Rally.
Sold both the GPz1100B1 and the ZX1100A1. Need to finance a legal case against my estranged wife so my only liquid assets, my bikes need to go, will try to keep the z900A4, the GPz1100B2 and the GPz900R.
May 2009
Picked up 2 GPz1100 (ZX1100A1), one is a goer the other needs some work.. z900-A4 engine stripped, cleaned and ready to assembly, starter clutch removed from kz650 and parts ordered for it.
April 2009
Rides and rally's.
March 2009
Picked up a 1980 kz650F1 from Sydney. Engine runs and it rides OK, needs starter clutch work and fork seals as well as a cleanup and full service. The z900-A4 engine has been stripped and photographed.
February 2009
Fixed some broken site links and worked on mirror site at freewebs using a newer design format. lots of work still to do.
November 2008
Work on z900-A4 continues, service on GPz1100B2 after GP trip. Frame brackets to be repaired for gear sack. House nearly destroyed in Mini-Cyclone!
October 2008
Philip Island GP!
September 2008
Heading to GP at end of September
August 2008
GPz1100B2, minor issues, GPz900R cooling system repairs, z900 rebuild in progress.
July 2008
z900 rebuild well underway. Purchased GPz1100B1 DFI fitted and working.
May 2008
GPz1100B2 roadworthy obtained.
April 2008
GPz900R registered!
z900-A4 frame repaired, work on GPz1100B2 progressing.
March 2008
Gpz900R completed, z900-A4 stripped and getting frame straightened and repaired.
March 2008
GPz1100B2 ready to receive registration. GPz900R Registered and running.
February 2008
GPz1100B2 Purchased and initial work started.
January 2008
Not much to report.
December 2007
GPz is together and rolling, 3 of 11 body pieces are complete and ready to install. z900 pissing oil (on the bright side my left boot is really shiny :)
November 2007
Work on the GPz is roaring ahead, some of the bodywork is in getting painted, front end is assembled, brakes installed and bled, new disks fitted and swingarm bearings fitted ready for swingarm installation.
October 2007
Lots of work on the z900-A4, strip of the rear of the GPz900R and lots of alloy and steel parts cleaned up and clear coated.
August 2007
Rebuild of the callipers on the GPz900R and assembly of the front headlight of the z1000A2 as well as the Koni shocks and rear end.
July 2007
Rebuild of the carbs on the z900-A4, parts arrived for the Gpz900R and z1000A2
June 2007
Assembly of the front end of the z900-A4 and some ignition work.
May 2007
More work done on GPz 900R and Z1000A2, Forks on z900A4 in getting hard chromed.
Aprill 2007
Purchase of 1985 Gpz900R - Pictures to follow.
March 2007
Evaluation of the z1A project to finish it off.
February 2007
Some work done on re-assembling the GPz front end. Chrome parts for the z1000A2 came in. Some assembly work on the z1000A2
January 2007
Still getting parts for the GPz900R roadworthy project. Parts coming in for the z1000A2, ready to assemble the front end. Ready to start on z900-A4 carbs then need to do z1000A2 carbs. Conondale Rally was a blast - 4 days of work and partying! Go the Z-Owners!!!
November 2011
Imbil rally!
Zephyr 550 serviced and returned back to Heather, now on hunt for a 550 or 750 for myself.
October 2011
GPz1100 forks at Hardchromers, ELR paint job on tank progressing. Now at frame assembly stage, machining new fasteners to fit GPz1100. Need new front tyre shortly!.
August 2011
Re-assembly of GPz1100 has begun, parts slowing being sent out for cleaning and others for powder coating, rear-end assembled to frame. Forks to go in next for hard chroming, then front end assembly scheduled. Tank spray puttied ready for sanding and first colour coat.
July 2011
Sent box of GPz1100 metal parts to get powder coated. Frame in getting done also. Bearings for swingarm arrived.
June 2011
Stripped GPz1100 and started to prep parts.
May 2011
GPz1100B2 Frame back from the engineers, work progressing slowly.
March 2011
Started to strip GPz900R, Alternator dead and Water pump leaking, new pump on the way. Needs strip and cleanup, a full service, 1 carby boot but otherwise OK.
Feb 2011
Final prep for WSBK 2011 ride.
October 2010
Sourcing parts for the GPz900.
Sourcing a cam chain tensioner for the z900 and head gasket to boot.
Started planning the rebuild of the GPz1100, wheels done!
August - September
z650 work.
GPz900R work
z900 Head rebuild
July 2010
Bearings arrived for z650, GPz1100B2 and GPz900R-A2
June 2010
Work on z650 wiring harness complete and installed - all OK!
Parts ordered for Hetaher's GPz900
WSBK2011 ride announced and organization started.
May 2010
30th - z650 Registered! More shiny parts ordered and some arrived.
Working like mad to get z650 roadworthy and reassembled.
April 2010
1977 z650B1 Stripped and sent to powder coater.
Parts for z900 arrived. GPz900R serviced and cleaned, oil change due this month.
March 2010
WSBK Gathering of the faithful 100% success!
z650 Stripped ready for powder coating.
GPz1100 serviced and carb Sync. GPz900R - Needs strip down and service.
February 2010
Prep for WSBK ride...
January 2010
Installed z900 wiring harness. Stripped z650 wiring and some body parts off.
December
Worked on z900 wiring harness, cylinder head cleaned. Soldered DFI system on GPz1100.
November
z900 engine install, DFI system on Gpz1100 to be soldered up and re-installed.
October
Tickets for super bikes, z900 engine assembly in good progress, z650 ready to register.
Z-Owners Maintenance day at my place.
September
Z900 engine rebuild coming along, zx1100 EFI serviced, z650 ready for rego and funeral for Dave Jones.
August 2009
zx1100-A1 EFI issues sorted, basic maintenance performed on bike. Test ride on deserted highway reaches 195 with no effort (with passenger holding on for deal life) and the power delivery is AWESOME! What a good score for $1500. z650 carbs synced and electrical issues corrected. Needs fork seals and front caliper stripped and cleaned.
Second zx1100A1 started first go and idles but restarts are an issue. More work needed
July 2009
z650 is running, test ride made up and down the street, exhaust leaking and may need fork seals. Otherwise all good! Updated web pages for z900A4 and z650.
June 2009
Update - Sold all Honda parts and the 750 cafe racer project as well as the z1000G.
Rode to Dalveen for the Granite Gnome Rally.
Sold both the GPz1100B1 and the ZX1100A1. Need to finance a legal case against my estranged wife so my only liquid assets, my bikes need to go, will try to keep the z900A4, the GPz1100B2 and the GPz900R.
May 2009
Picked up 2 GPz1100 (ZX1100A1), one is a goer the other needs some work.. z900-A4 engine stripped, cleaned and ready to assembly, starter clutch removed from kz650 and parts ordered for it.
April 2009
Rides and rally's.
March 2009
Picked up a 1980 kz650F1 from Sydney. Engine runs and it rides OK, needs starter clutch work and fork seals as well as a cleanup and full service. The z900-A4 engine has been stripped and photographed.
February 2009
Fixed some broken site links and worked on mirror site at freewebs using a newer design format. lots of work still to do.
November 2008
Work on z900-A4 continues, service on GPz1100B2 after GP trip. Frame brackets to be repaired for gear sack. House nearly destroyed in Mini-Cyclone!
October 2008
Philip Island GP!
September 2008
Heading to GP at end of September
August 2008
GPz1100B2, minor issues, GPz900R cooling system repairs, z900 rebuild in progress.
July 2008
z900 rebuild well underway. Purchased GPz1100B1 DFI fitted and working.
May 2008
GPz1100B2 roadworthy obtained.
April 2008
GPz900R registered!
z900-A4 frame repaired, work on GPz1100B2 progressing.
March 2008
Gpz900R completed, z900-A4 stripped and getting frame straightened and repaired.
March 2008
GPz1100B2 ready to receive registration. GPz900R Registered and running.
February 2008
GPz1100B2 Purchased and initial work started.
January 2008
Not much to report.
December 2007
GPz is together and rolling, 3 of 11 body pieces are complete and ready to install. z900 pissing oil (on the bright side my left boot is really shiny :)
November 2007
Work on the GPz is roaring ahead, some of the bodywork is in getting painted, front end is assembled, brakes installed and bled, new disks fitted and swingarm bearings fitted ready for swingarm installation.
October 2007
Lots of work on the z900-A4, strip of the rear of the GPz900R and lots of alloy and steel parts cleaned up and clear coated.
August 2007
Rebuild of the callipers on the GPz900R and assembly of the front headlight of the z1000A2 as well as the Koni shocks and rear end.
July 2007
Rebuild of the carbs on the z900-A4, parts arrived for the Gpz900R and z1000A2
June 2007
Assembly of the front end of the z900-A4 and some ignition work.
May 2007
More work done on GPz 900R and Z1000A2, Forks on z900A4 in getting hard chromed.
Aprill 2007
Purchase of 1985 Gpz900R - Pictures to follow.
March 2007
Evaluation of the z1A project to finish it off.
February 2007
Some work done on re-assembling the GPz front end. Chrome parts for the z1000A2 came in. Some assembly work on the z1000A2
January 2007
Still getting parts for the GPz900R roadworthy project. Parts coming in for the z1000A2, ready to assemble the front end. Ready to start on z900-A4 carbs then need to do z1000A2 carbs. Conondale Rally was a blast - 4 days of work and partying! Go the Z-Owners!!!
Ultra Cool 750 Chopper - I want to build (someday), this must be one of the coolest looking CB750 choppers I have seen for some years and I intend to build something in this style.
Last updated 17th November 2011
Contact me using my Gmail account(s):
"z900collector AT gmail DOT com" <- HINT - Read it out loud.
or
"sid DOT young AT gmail DOT com"
If you have contacted me in the past, send me an update, I'm always keen to hear how other project bikes are going.
36499
Rust Removal Experiments
I get asked questions about bikes from all over the world, every week numerous emails arrive asking about how to do something or seeking my opinion on a bike or technique, one email was on using Molasses for rust removal. Eager to expand our knowledge, Heather and I went for a ride and got some Molasses from her brother (he has a few head of cattle on a farm) and mixed enough up to make up 50L to do some experiments with various metal object (z650 exhaust headers and old fasteners). One thing I discovered is Molasses tastes just like licorice :) no wonder the cows love it! It also eats rust really well with no effect on the non-rusty metal parts! After one week the rust has been removed from most of the header pipe, it has also de-coked the inside of the pipes which would make it OK to send to a chrome works as there is nothing left to contaminate the chrome tank's electrolyte mix.
We plan to leave the parts in for 3 weeks, checking it every few days. The mix ratio is 10L of Hot water to 1L of Molasses and stir it so it does not initially settle. After that you just sit the items in the tank (in a plastic carry holder is fine) and the mix does its thing. The exhaust pipe will need a going over with the Gurney (water blaster) when we are ready to remove it and repaint the heads, as for te rusty bolts, most were shiny after a week, I will put them back on the 650 and see how long they last before they start to oxidize again. So at this stage, Molasses looks like a brilliant method of pre-cleaning steel. I have taken some before and after shots to show the difference.
I get asked questions about bikes from all over the world, every week numerous emails arrive asking about how to do something or seeking my opinion on a bike or technique, one email was on using Molasses for rust removal. Eager to expand our knowledge, Heather and I went for a ride and got some Molasses from her brother (he has a few head of cattle on a farm) and mixed enough up to make up 50L to do some experiments with various metal object (z650 exhaust headers and old fasteners). One thing I discovered is Molasses tastes just like licorice :) no wonder the cows love it! It also eats rust really well with no effect on the non-rusty metal parts! After one week the rust has been removed from most of the header pipe, it has also de-coked the inside of the pipes which would make it OK to send to a chrome works as there is nothing left to contaminate the chrome tank's electrolyte mix.
We plan to leave the parts in for 3 weeks, checking it every few days. The mix ratio is 10L of Hot water to 1L of Molasses and stir it so it does not initially settle. After that you just sit the items in the tank (in a plastic carry holder is fine) and the mix does its thing. The exhaust pipe will need a going over with the Gurney (water blaster) when we are ready to remove it and repaint the heads, as for te rusty bolts, most were shiny after a week, I will put them back on the 650 and see how long they last before they start to oxidize again. So at this stage, Molasses looks like a brilliant method of pre-cleaning steel. I have taken some before and after shots to show the difference.
