Hi everyone,
Lots of first for me these days - first Kawasaki, first time attempting to build/modify a bike, first time posting on this awesome KZ forum. So be gentle, I'm a newbie. I've already learned so much and gotten so much inspiration from reading about other user's builds, so I wanted to start a thread about my own project, both to sorta keep track of it for myself, to hopefully get some helpful insight from you all, and to maybe even inspire someone else perusing the interwebs to get started on their own project.
I've been riding since my early 20's, but haven't had a bike for a few years, and I never really learned any of the mechanics behind the bikes I rode or even how to fix basic issues. I've been itching to get back in the saddle AND to learn more about how these creatures work, so a couple of weeks ago I threw caution to the wind and bought a "project bike". The story goes that this bike was running well, but was dirty, so after riding it for a while the previous owner decided to take it apart and clean it up. Tank, covers, fairing (which I'm selling) was all cleaned, painted and cleared. The frame was powdercoated. The external engine parts were meticulously cleaned. And then he (the previous owner) had to move to the west coast. So for five years this bike - taken apart and in boxes - has been sitting in a garage in SoCal. Everything looks great, so I'm very optimistic, though I obviously haven't heard the engine running yet.
Here's what it looked like when I brought it home:
And here's where I'm currently at:
The goal is a stripped down street bike with just a hint of "cafe" in it. Nothing too crazy. I wanna keep some of the Police heritage, but get rid of the fairing and the boxes.
I've been doing mostly cosmetic stuff, skirting around the real issue of getting the engine running, while I've been familiarizing myself with the bike and the manual, getting spare parts, etc. I've cleaned and painted brake calipers, rear shocks, and other minor things to get them nice and shiny. I've changed tires, changed fork oil and checked for leaks, etc. I've cleaned and lubed bolts, bearings, etc. Changed a couple of the gaskets already, waiting on new o-rings all around. Lots of stuff, but all minor and somewhat insignificant. On to the important things now; the engine.
When I got the bike, the top end of the engine was off. The bottom has not been split open and I don't intend to do so, if I can avoid it. A few questions have popped up:
1. Am I right in not being intimated too much by this project, thinking I can get a machine like this running myself? Or am I putting myself in danger by trying to make a 1000cc bike rideable with no prior knowledge of mechanics?
2. Is it OK to reuse the piston rings? I've carefully cleaned them (and the pistons) and they seem to be in good condition. I've ready conflicting opinions on this. I'm getting new snap rings for the piston pins.
3. Is there anything in particular I should look out for when cleaning the camshaft and valves? They have some light surface rust, but generally look good. I know I have to be very careful. Any tips of the best way to do this?
4. Is there a way to test the pistons and cylinders before putting it all back on the bike?
5. And finally - as another project while I'm waiting for the parts I need for the engine reassembly - I've been working on a new wiring harness diagram. I want to get rid of all the police wiring and go as basic as possible. I drew this up by referencing the Clymer manual and original diagram, and the amazing motorcycle wiring guide by John Partridge. Can anyone with electrical knowledge tell me if this diagram would work?
www.dropbox.com/s/jq0ikdt2e0qq2vk/KZ1000...g%20Diagram.png?dl=0
Thanks so much for keeping this forum alive and for looking out for newbies like myself. It's been an invaluable source already!