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TOPIC: Retroactive KZ750E Project Thread

Retroactive KZ750E Project Thread 13 Jan 2017 10:11 #752088

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And speaking of plated parts...

Used a "copy cad" zinc plating kit from Caswell's Plating. I've got a power supply now instead of using a battery for power but you get the idea...












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Retroactive KZ750E Project Thread 13 Jan 2017 10:15 #752089

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Working on the gauges. Condensation behind the glass and corrosion on the outside bezel. Gently pried off the sealing ring and took the units apart. Going to bead blast the housing and repaint next.












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Retroactive KZ750E Project Thread 13 Jan 2017 10:17 #752090

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Also cleaned up and clear coated the fork sliders and footpeg brackets. Bead blasted off the corrosion and rubbed them down with gray scotchbrite before shooting the clear.





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Retroactive KZ750E Project Thread 13 Jan 2017 10:21 #752091

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Forks got new seals, Sonic springs, Racetech emulators, and of course new oil.

"Clocks" (for you UK guys) turned out nice.













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Retroactive KZ750E Project Thread 13 Jan 2017 10:23 #752092

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Put new wires in the coils. Was able to pull the exterior protective shield tubing off the old wires and install them on the new wires. Installed new plug caps too. Went with NGK's from Z1. Not OEM but that's okay for this project.



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Retroactive KZ750E Project Thread 13 Jan 2017 10:26 #752093

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Rolling chassis...






[img]https://farm5.staticflickr.com/4292/35441854834_563af4f84b_b.jpg[/img [img]https://farm5.staticflickr.com/4300/35469902153_ff7d27861a_b.jpg



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Retroactive KZ750E Project Thread 13 Jan 2017 10:27 #752094

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Retroactive KZ750E Project Thread 13 Jan 2017 10:29 #752095

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Put the brake lines together today. Earl's Speed-Seal. Took some photos in anticipation of making a tutorial. We all know how much everyone likes photos around here...

Old lines...





New Earl's parts...





Tools...

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Retroactive KZ750E Project Thread 13 Jan 2017 10:32 #752096

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Retroactive KZ750E Project Thread 13 Jan 2017 10:34 #752097

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Look down inside the ferrule and make sure the inner teflon liner is fully seated down to the step inside the ferrule.









Shove the hose on firmly while tightening the nut. Tighten almost all the way, but stop just short so the hose end can be clocked with the other.



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Retroactive KZ750E Project Thread 13 Jan 2017 10:35 #752098

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Retroactive KZ750E Project Thread 13 Jan 2017 10:36 #752100

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Whack the chisel with the mini sledge...







Check clocking of the hose ends by pressing one on the table and looking at the other. On this hose they are 90 degrees from each other.




Install the other hose end, clock the position carefully, and you are done. I used non adjustable hose ends but they work out fine. You just need to be careful to stop a little short of fully tight so you can get the clocking right.

Repeat everything three more times and...
Some heat shrink tubing can be used to cover up where the vinyl coating was removed. Next time...



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Retroactive KZ750E Project Thread 13 Jan 2017 10:39 #752101

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Cleaned up the harness best I could and re-wrapped it with Elliott Tape EE 201 non adhesive tape. Good stuff. The 201 flavor is the high temp stuff so heat shouldn't be an issue. Non adhesive like the stock harness wrap so the harness doesn't turn into a sticky mess.

Used a combination of Deoxit, Scotchbrite, stainless steel wire brush, and a dremel tool to clean corrosion off the electrical contacts. Pinched closed the female terminals where ever possible.

Bought some new electrical terminals and crimping pliers from Vintage Connection. These things roll over the edges over on the terminals just like the OEM terminals. They seem more secure than the smash flat terminals that are so common these days.

Snuck in a SH-775 R/R under the battery box. Had to make a bracket first but it turned out pretty well.






[/url]

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Retroactive KZ750E Project Thread 13 Jan 2017 10:41 #752102

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Chassis electrical is all hooked up and working. Installed GPz style turn signals, K&S brand. They look good but are pretty junky on the inside (cheap electrical socket).










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Retroactive KZ750E Project Thread 13 Jan 2017 10:43 #752103

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More blasting and a little seat pan repair...








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Retroactive KZ750E Project Thread 13 Jan 2017 10:48 #752104

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Painted up the seat pan and installed a Pit Replica seat cover. The cover itself is an excellent visual reproduction of the 1981 750E pattern. Unfortunately, the lower flange area is poorly executed and is easy to tear. I wound up having to get a second cover and was more careful during install the second time around...







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Retroactive KZ750E Project Thread 13 Jan 2017 10:50 #752105

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Bought some clear, basecoat, and hardener. NOT cheap. The clear is the "new" 2.1 VOC flavor. Translated that means it's low solids and thin. In other words three coats needed instead of the old two. Hum, makes one wonder if it actually results in less crap going into the air or what? At any rate, that's how it is in California these days. Took a flier on the color: bought a pint of black and a pint of dark pearl blue and had them mixed together. Going for a black look from distance, but with some pearl blue coming though when you get closer. We'll see.

Since the original paint is so chalky and tore up I'm removing as much as possible before prime. Two part epoxy for that of course. One of the side covers had a swale in it so filled it with body mud. Good fun...







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Retroactive KZ750E Project Thread 13 Jan 2017 10:53 #752106

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Any color you want as long as it's black.;)

Actually, the color looks black until you get it out in the sun then it looks pearl blue. Just the look I was after.

Had a hard time with the USC01 clear. It goes on dry looking then lays down. Have a few runs because I laid it on too thick. Going to color sand anyway so not a huge problem. Pin stripes will go down after sanding then two more clear layers over the graphics. Now that everything's cleared I can take my time.











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Retroactive KZ750E Project Thread 13 Jan 2017 10:55 #752107

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Color sanded the clear. Used a gray scotchbrite pad to level the orange peel.






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Retroactive KZ750E Project Thread 13 Jan 2017 10:58 #752108

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Bought 3M brand stripes, and ordered direct from 3M because I wanted to make sure to get fresh stock. The stripes themselves are sort of gummy in consistency, and stretch easily for the turns.

Allowed the stripes to cure up for a day or so and then it's more clear...







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