82 KZ750 Resto / Cafe *updated*

Hello All. I've always been into cars so forums aren't new to me though bikes are. Not only is this going to be my first build it's my first bike. Exciting right?

So onto the bike, an 82 Kawasaki KZ750 LTD H3... Picked it up about 3 weeks ago with 18,270 on the clock for $540. It runs well but needs work after sitting outside for at least 8 years. The PO says he covered it but seeing all the rust makes me think otherwise.




My goals are to get it running perfect and fix everything that's wrong first. Then i would like to go for a comfortable brat look. Superbike bars, flat seat, no fenders etc. So far I've only tackled cleaning, an oil change, changed the plugs and air filter (k&n) and got the blinker and tail light working again.

There are a few things that have me stuck being a newbie and all.

-The front brakes are stuck. I dissembled the calipers and re-greased all the pins and bolts. Next step will be a brake bleed and then a caliper / MC rebuild if the bleed doesn't help. Anything I'm missing here?
-Bike sputters and doesn't produce sufficient power from about 1200-3000. I'm assuming this is a clogged jet or other carb issue. The header pipe on cylinder 3 takes longer to warm then the others so that's where I'll start, any other suggestions?
-Having issue on cold starts. It takes a long time for the starter to catch, once it catches once it''ll fire right up. Lost on this one? Starter rebuild in my near future?

Thanks for the help in advance. I'm going to try to update as much as possible!!

Jrbrownie00 wrote: -The front brakes are stuck. I dissembled the calipers and re-greased all the pins and bolts. Next step will be a brake bleed and then a caliper / MC rebuild if the bleed doesn't help. Anything I'm missing here?
-Bike sputters and doesn't produce sufficient power from about 1200-3000. I'm assuming this is a clogged jet or other carb issue. The header pipe on cylinder 3 takes longer to warm then the others so that's where I'll start, any other suggestions?
-Having issue on cold starts. It takes a long time for the starter to catch, once it catches once it''ll fire right up. Lost on this one? Starter rebuild in my near future?

Welcome.
Does the caliper piston move in the bore? If not, you'll need to take it apart and clean it. You may need to replace some seals.
For the sputter you'll need to pull the carb and clean it. Since you are doing one you might as well do them all.
The cold start issue is fairly common. It sounds like the starter clutch has had it. Not an impossible fix but you'll be taking the engine out to get at it. Do a search on the forum. A lot of us have tackled that particular gremlin.

I bought the parts for the carb refresh today, hopefully that will be that. The pistons moved when pressed with pliers. I may take them apart for a good cleaning anyway.

I have already done the research on the starter clutch, i was really hoping there was a different answer! :ohmy:

No.1 get a repair manual for that bike.
No.2 DynoJet still sells a jet kit for that bike.

I ordered a Haynes manual and am patiently awaiting it's arrival. For $25 it seems well worth it.

You would have been better off to order a Kawasaki Service Manual (FSM), and you still should do so. Haynes and Clymer manuals are not as complete as the FSM. Ed

Jrbrownie00 wrote: I have already done the research on the starter clutch, i was really hoping there was a different answer! :ohmy:

So do all that live to see such times...but that is not for them to decide...

Welcome,
Take your time. There are a lot of good ideas and plenty of people that know their stuff on thiis site. Keep us postd. I have to work on mine also.
Be well...

Making progress, with school and work I haven't been able to give it my full attention. Wire brushed, removed, sand blasted (have one at work) and this was after one coat of POR-15.





Carbs and petcock are out. Replacing the float bowl gaskets/float needles and rebuilding the petcock even though I'm not sure it needed it.

which type of wheel are you going to use? spoked or Mag?

If you'd rather go with Spoked, then maybe we could switch.

how do you like the POR-15?

popssss wrote: which type of wheel are you going to use? spoked or Mag?

If you'd rather go with Spoked, then maybe we could switch.

how do you like the POR-15?

I was just going to go with the mags because it's what I've got. Where are you located?

The heads aren't on the bike yet but it seems pretty good. The real test will be durability. It's easy to apply.

more progress!!

Does anyone know how to make the front blinkers work with a blinker that only has 2 leads?