Saving a '81 KZ750-E

I found some pan head screws today that allowed the bars to move another 3/4" forward. I will use this position to get the steering stops dialed in. I'm planning on about a 1/2" of clearance at the tank at full turn.

After the steering stops are finished, I have to make up my mind on what turn signals I will use. The mounts for the turn signals should be the last modification to frame before it can be sent out for powder coating. There is a dizzying amount of aftermarket turn signals out there! I have been hesitant to look at LED units since I doubt the stock relay will blink with such a small load. Has anyone tried upgrading these older systems to an LED style? If so, what blinker relay was used?

Here is a comparison of the difference in handlebar position with the bolt change.

Before


After

LED turn signals only work with an load independent flasher relay.

I used LED turn signals on my baja bug, and put in a "no load" relay designed for LED's. It still wouldn't blink with 25 LED's on each circuit. I ended up having to put in a normal bulb side indicator in the front wheel well just to get it to blink. Due to that, I am not sure I trust "no load" relays. If someone has actual experience with a certain brand of relay with these older bikes I would like to know.

I spent a couple hours today just cleaning up the frame with an air grinder. What Kawasaki left on and around their production welds was pretty disappointing to me. But if I am going to powder coat it, may as well fix all the ugly stuff.

I started to clean all the other bracketry that will get coated with the frame. I love my blast cabinet!

Trying to decide to reduce the size of the stock rear signal brackets, or cut them all the way off and make my own to fit the turn signals I buy. I'm not putting the grab rails back on, or the rear foot pegs. But thinking leaving it optional for a future owner may be a good thing.

I finally started looking at the carburetors today. With some WD40 I was able to get the choke and throttle shafts moving again. Decided to get the vacuum pistons out and see how the diaphragms are looking. All the pistons were frozen in place. After liberal quantities of WD40, I was able to get 3 of the 4 out. Both outers were more difficult, with one of them being the last remaining. I hope I am up to the task of saving these!

The diaphragms are still pretty pliable and crack free. The corrosion will be the big deal in getting these working or not.

Heat on the body will soften the varnish holding the slide.

Have you encountered any problems reusing the choke shaft (if it's corrosion free)? Other than the mushroomed screws you mentioned in another thread?