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Saving a '81 KZ750-E

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28 Jan 2020 20:19 #818146 by Nessism
Replied by Nessism on topic Saving a '81 KZ750-E
Oops, sorry about the pad recommendation. Not sure what I was thinking since you have photos of the front end and brakes. Anyway, glad it helped with the rear.

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31 Jan 2020 11:53 #818310 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I have lost track of how many times I have assembled, and disassembled, this ignition/gauge/headlight bracket. I decided I needed to fix a few areas that showed up after paint. Hammertone won't hide everything. New finish is back on.


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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31 Jan 2020 15:38 #818316 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Looks like I get to add hand controls to the list...


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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  • Scirocco
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  • Premium Member
  • Never change a running system
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31 Jan 2020 16:04 #818317 by Scirocco
Replied by Scirocco on topic Saving a '81 KZ750-E
These handle bar controls are worth to be rebuild....

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31 Jan 2020 16:45 #818319 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I can't get the switches out, I am afraid to break them.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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31 Jan 2020 17:20 #818321 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Since I am not certain how these need to be removed, can anyone give me some tips which way these switches come out? I have tried to pry (gently). All screws have been removed.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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  • Scirocco
  • Offline
  • Premium Member
  • Never change a running system
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31 Jan 2020 18:23 #818322 by Scirocco
Replied by Scirocco on topic Saving a '81 KZ750-E
Try carb dip or a Ultra sonic cleaner.

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31 Jan 2020 18:25 #818323 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Currently soaking in WD40 for starters.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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  • DoctoRot
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  • Sustaining Member
  • Oh, the usual... I bowl, I drive around...
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31 Jan 2020 22:40 #818327 by DoctoRot
Replied by DoctoRot on topic Saving a '81 KZ750-E
No eBay APP ID and/or Cert ID defined in Kunena configurationrebuilding those switches might be a test of insanity. they look pretty shot. if if you pretty l them up i think the terminals and contact points will be still problematic with that much corrosion. You can get some reproduction KZ900 switches that work well, and have a very similar look. I run them on both my KZ's. only downside is the kill switch is orientated right which is easy to accidentally hit with your hand. I solved that problem with quick turn throttle sleeves.

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01 Feb 2020 00:25 - 01 Feb 2020 00:28 #818330 by calum
Replied by calum on topic Saving a '81 KZ750-E
I've been going back and forward on this as well. I've got two sets of original switches and after blasting the cases are OK. The contacts may need some cleaning and soldering, but should be alright. My main problem is getting the text looking good (grooves are pretty shallow and filling them with paint and sanding off the excess didn't always work).
Pulling them apart shouldn't be a problem. There is a screw in the side of the high beam switch that needs to come out, the kill switch has a screw underneath. I seem to remember the hazard light switch being a bit less obvious. There was a screw somewhere that needed to come out. If you have any problems let me know - I can take another look at it.

Edit: if you do decide to restore them I have a complete set of spares here (both my sets were working before I pulled them apart).
Last edit: 01 Feb 2020 00:28 by calum.

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01 Feb 2020 07:30 #818355 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I will attempt to save the originals until it becomes obvious they can't be beaten into submission. As far as filling the text with paint, I have some dental picks and a lot of spare time. I have been trying to repaint my side cover emblems with limited success, mostly because I am a picky bastard. So far the first one is not to my liking. I am trying to get the letters done in gold, so sanding the tops won't work. But back to the switches... DoctoRot, do you know if the wiring on those replacements match the KZ750? That is a good fall back option if mine prove to be trash. I had never considered using switches from another model/bike. Thanks for the link!

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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01 Feb 2020 10:04 #818360 by deano68
Replied by deano68 on topic Saving a '81 KZ750-E
i used ER6 switch gear on mine they reqired very little wiring work as the colours are the same as other zeds ive worked on OEM always works better for me than repro stuff seems to

76 KZ 400
78 KZ 650
82 Z 750(4)
80 KZ1000 ltd project
82 CSR 1000 work in progress
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