TOPIC:

Again huge tachs.

Spark plug and wires.

Rear Shock.

Front Wheel.

Engine...Needs cleaned so BAD!!!

Look at that light I could swear a train was coming....

Full Bike Shot.

What I wanted to do was buy all of my new hardware connect it while the bike was still together THEN begin the process of COMPLETLY breaking the bike down.

Remove the seat.

Inspect wires.

Pull Petcock so we can remove tank.

Like a chick w/no bra

Nakedness!!!!

Tank!

Rear Fender wiring.

Rear Fender removal.

She's getting more naked.

rear fender removed.

Tail Light Taken off.

Good lord there is a lot of sanding involved in this process.

Getting rid of the club gold!!!

Front fender.

Rear Fender Before Sanding

Front Fender about done.

Front Fender

Both fenders down to metal.

And again down to metal.

Gotta make sure I get a beer in the shot.

New Items.

headlight
taillight
blinkers
grips
pegs
speedo/tach
speedo cable

The new items start to arrive!!

speedo cable/clamps for new headlight.

Pegs.

speedo.

Grips

mirrors.

So at this point the new hardware starts to arrive and the new headlight and speedo are going to require some cutting of the wires. So I opted to make sure everything was working before I gutted her. Here is the mock up process for the new hardware.

Raise the bike off the ground. Using a Craftsman motorcycle jack for the job. Very good piece of equipment.

Taken off the old headlight and mounted the new headlights/blinders no wiring yet.

Picture of my new headlight housing.

New blinker vs. old blinker. The older ones were once used to land planes I swear it!!!!

Back togehter. Still not wired just mounted and ready to roll.




Tach/Speedo.

At this point the new hardware is on. Again we haven't begun to wire it up just mocked up the installation to make sure we could get everything attached and the only thing we'd be fighting is wires. And yes that can be a nighmare in and of itself!! While the bike is waiting for wiring to begin we started to attempt to fix the tank. What happened to the tank? Well my buddy who you will see in some of the photos popped a whole in my tank. My tank came with the kawasaki emblems on the bike but it was rusting pretty bad under the emblems. In an attempt to clean that rust my buddy got just a little careless and popped a whole through the rust with a screwdriver. We have tried everything to fix that whole. We attempted to use jbweld but it didn't seem to hold that well. Then we attempted to use plumbers welding. Still no good but here is some pictures of the tank when we tried the plumbers welding.

Materials

More materials.



Tank after sanding area

More tank

Tank again.

Starting to attempt to fill with weld.





Finished and it feels like it might hold.

Sanding down the edges.

After all of this it still did not hold. During sanding the metal begin to fall apart in pieces. I didn't take anymore pictures because this was depressing and aggrivating!!!

Here are the pictures of the rattle can job that took off the gold and was painted silver on the rims.

Gold Forks!! And the ugly turn signals.

Prep work is important.

My rattlecan buddy with a jack and coke. Don't let drunk people paint.

Is that a tire hanging from your garage? H3ll yeah!!!!

The hanging tire.

This is how the rims got to being painted silver. Yeah I know rattle can isn't the best in the world but just look at the gold one more time and tell me you wouldn't do it?

So at this point I have a motorcycle rattle canned silver. With some new pieces mocked up. But still no wiring accomplished. Over the next month we worked on the wiring we had to splice into the head lights and make the speedo work that was the hardest part. Ha! Ever cut the speedo off a spectre...those things were wired with all kind of xtra goodies. So we had to cut and lable cut and label. I wished I had taken more pictures but truth be told this job required a voltometer, a wiring diagram (FOR YOUR YEAR!), and a 12 pack of beer. And the pictures were really of no use becuase it just didn't do the overall insanity of cutting into your wires and justice.

The wiring was done though and we were able to get blinkers and headlight. And for once my highbeam acutally worked!! We ran into all sorts of troubles like the ground being on a relay which means that if one thing isn't right EVERYTHING is wrong. After hours of working gotta give props to my buddy (seen in some of the pictures) for his help here he's a wiring genius and did a lot of the wiring.

From here i ended up with a bike that still started and was mocked up but needed to have the wires cleaned up. Well that required me to take the harness off to make it 'right'. Enter tearing the bike down........

Some websites for electrical connectors in the wiring are:

1.www.easternbeaver.com
2.www.vintageconnections.com
3.www.electricalconnection.com
4.www.z1enterprises.com

Cool thanks for the links mfolks. I know about z1Enterprise great company that gets my votes all the way. For anyone else hopefully those links will help? I know I had to do some googling to get the diagrams I wanted.

diagrams.kz650.info/wiring/images/KZ650-F1.jpg

I learned a lesson with bondo. Less is always better. You have to learn somewhere I guess. I went out to the net and did some resarch on bondo and thought ah what the h3ll this will be simple your just trying to shape it. That's the 1st mistake.....
Prepping fender for bondo.

LOL Ok here was my rear fender with the bondo. Someone asked me if I was trying to frost a cake? Less is better bad thing is I did the front fender just as bad.

Sanding Bondo Off!!!

Sanding Bondo Off!!!!

As you can see I Was using a piece of sandaper in my hand. Well that got tiresome really quickly so I decided to cheat and use a power sander.

So here are a couple pictures of the prepped tank and the bike before we started the tear down. Notice the bike has all the new hardware on it and it all is functioning correctly.

Tank

Tank

Bike