Hi There - First Project Bike (Dial-up Beware)

Hello! I've been lurking for a little while before registering. KZRider is a great forum and I am so happy that I've stumbled across it.

About a month ago, I purchased a non-running 1981 KZ750 LTD for $150. My dream would be to create a streetfighter/cafe racer machine. My realistic intent, however, is to learn how to turn a wrench so that I can eventually do work on my Bandit 1200.

Here are a few pictures for your viewing pleasure.

Here is the KZ750 after being unloaded at its new home...


Check out the oil all over the exhaust...


Here is the start of teardown...


These carbs are much more nasty in person...




Look how dirty the air vacuum valve cover is....


Check out the hole in top crankcase; what the heck did that?


All I've been able to do for the day...


Fortunately, I can take my time doing this. I am being methodical. I'm bagging bolts, nuts, and small parts with labels on the bags. I am labeling each wire I disconnect so that rebuild will go easier. Also, I am taking a lot of pictures so that I can see how things looked when it was together. Of course, I have the shop manual as well.

This is a daunting task for me, but I figure the worst case senario is that I sell off all of the parts to recoup my money. Other than that, its not like I'm going to break anything too badly. Its not like the bike was running in the first place.

Wish me luck.

Post edited by: pugz, at: 2006/03/29 12:30

Welcome aboard. Looks like you know what your doing and are actually doing it (I tell myself to be careful about these things but then dont)

Keep the pics coming, its fun to see your work as it comes along.

Welcome aboard, VA.

You've embarked on an amazing learning experience. These bikes can teach you so much about a lot of things including yourself. Plus it's so much fun to work out your plans for it.

As you work through things, take plenty of pictures (something I fail to do often enough) so you have something to refer back to. Plus, they'll give you a benchmark in the future.

It looks like you're well on your way.

Good luck!

- Nate >>

It doesn't seem like much, but I worked my tush off after work. My goal was to get the wiring harness out. Wow. That was a tedious task because I labeled every stupid wire. Hopefully, it'll be worth the trouble.







Post edited by: pugz, at: 2006/03/29 12:32

Welcome to KZr, VA.

A little rough around the edges, but I think you got a decent deal on your bike for $150.


The "hole" you're talking about, is it the one I circled in the pic of your valve cover?
If so, that "hole" is supposed to be there. It's the reed valve, and is Kawis stab at meeting EPA requirements (similar to smog equippment on a car).
But it's also supposed to have a cover on it (ref# 14075A and circled in red in the 2nd pic), which it is obviously missing. :ohmy:
You might be able to find one on eBay, either that or you could post an add in the wanted section of the classifieds forum here on this site to see if another member has an extra one kicking around.

FWIW, the OEM part# for that reed valve cover is 14075-5017, and also fits:
81~83 KZ650 CSR
84/85 ZN700 LTD (Shaft drive)
81~83 KZ750 LTD
83 KZ750 LTD Shaft drive)
91/92 ZR750 Zephyr

It might fit other models and years, but that's just what I quickly looked up on the Kawi site ( Kawasaki website )

Post edited by: RetroRiceRocketRider, at: 2006/03/27 23:50

One more try on the pic:

RetroRiceRocketRider:

I was refering to this:



You have reminded me of a question that went through my mind though. The Suzuki Bandit 1200 has an air system that most people remove. Do KZ riders mod the air vacuum system? Can the bike run without it?

That hole looks like the result of a broken connecting rod, or something was spilled there and it ate through the case. Probably the only real fix is another top half of the engine case. Things like that do come up on eBay. An alternate method would involve JB Weld, but I doubt that would look too attractive.

Your labeling each connection was wise. You will thank yourself later.

- Nate >>

Not a good idea to replace just 1/2 of a case, the cases are machined as a set and should be replaced as a set.

I just took a look at a 750 four motor to see if anything other than a rod could have done that, and I don't see anything else that could.

Assuming it was done by a connecting rod, then it would be much cheaper to buy a used motor than to repair that one. If the motor is still in the frame, put 12 volts to the starter and see if you can do a compression check, or take all the spark plugs out and put your thumb over #1 spark plug hole (the cylinder where the hole is) and see if it has any compression at all.
That is if the motor is not locked up because of a broken rod

Oh yeah, post the pic and the results of your compression test in the engine forum, I keep forgetting to look in this forum

Post edited by: steell, at: 2006/03/28 13:32

Hey Steell, how did the new guy get those giagantic photos in here?

Nevco48:
I have my photos hosted on a free site called photobucket.com. I then just cut and past the url inbetween the [img] [/img] tags. Walla! Personally, I try to post pics that way so it reduces the amount of space taken up on a forum's server.

What's up KZVA, another VA native here. Commonwealth -- represent! :laugh: if you're near Manassas you got a hand from me if you ever need it. Especially from now until my block comes back from APE.