Re-Build / Restoration Checklist(s)??

A newbie to motorcycle work would like to know if anyone has a Re-Build / Restoration Checklist that they have used for a project?

Maybe you post complete or partials (specific to a certain part of a build ie; chassis, carbs, engine, etc.) what you have here, and I'll work to edit and combine them into a comprehensive checklist to share.

Thanks,

Farnie

Hey Farnie,

It is a bit hard to have a general check list because it all depends on the condition of the bike. You may need a very small or very large check list. But let me give you my .02 without knowing the state of your project bike and assuming a stock restoration.

1. Check general condition of the engine.
a. Is it seized or not?
b. Will it start (make sure it has proper oil level)?
c. Determine what is required to make if run if it doesn't (carb clean/rebuild or ignition rehab or both)
2. Gas tank: look for internal rust and debris. Very important to make sure it is completely clean to avoid continuous problems with the carburetors.
3. Check tires, condition and age. Replace if older than 4 yrs or condition is not good.
4. Brakes: make sure the are functioning with no hydraulic leaks and have plenty left on the pads.
5. Forks: check level and condition of fluid and check for leaks.

Man that is not even the tip of the iceberg. O.K. I give up.

No doubt Joe....

30 Year old KZ and don't know the history, only one way to really go in my worthless opinion....

Number 1 on the list: OEM SERVICE MANUAL... Study it!

Engine alone:
* Split cases for internal inspections. Replace as required.
Crankshaft/Clutch housing/basket/plates/transmission/gears/oil pump etc...
New clutch plate(s) & springs.

* Complete engine oil seal and gasket kit....

* Pistons & rings
New rings & cylinder hone at least.
Looking for extra umphka, 1075 piston kit, cylinder boring required.

* Camshafts:
Looking for extra umphka, .365 at least. GPZ1100 OEM cams .375 lift...
Cam degreeing required!

* Valve job: new valves, seals, guides.
Looking for extra umphka, possibly enlarged valves, at least port & polish.

* Timing chain, guides, rollers, idler gear.

Drive Train:
* New chain & sprockets (front & rear)

Carbs:
* Rebuild now doubt.
Looking for extra umphka, smoothbores to go with head P&P.

Frame: if not modding (example mono swing arm), powder coat or paint.

Electrical:
NOTE: Pending operating/charging conditions, test/confirm first.

* Possibly new wiring harness.
* Possibly new stator/Dynamo...
* Possibly new combo rectifier/regulator.

Ignition: coils, plug wire set, ignition plate:
* Dyna S set w/coils/plug wires at least.

Suspension:
* Steering, swing arm, wheel bearings etc...
* Most likely new rear shocks.
* Rebuilt front shocks.

Tank/Plastics:
* Tank rusted thus treatment.
* Paint tank & plastics.
* New petcock.

Brakes:
* Master cylinder clean/rebuilds.
* New pads

New Tires:

New throttle, clutch & brake cables:


Ok, I'm with Joe, my brain is now toasted!.... :laugh:

Post the project w/images... We're picture whores here!

Welcome to the OBSESSED insanity....

re chroming where required, seat recovered/upholstered, clocks stripped, cleaned and recalibrated.
my brain was toast before i started my list :blink:

I've done a few bikes, for a "restoration" I:

1) get the thing running and make sure it shifts through the gears
2) tear the bike down, take photos and put small pieces in marked envelopes
3) send out all the hardware for replating, (probably most important step) also buy some spare hardware from the same era (Ebay) so you have extra. The biggest headache is having clean hardware handy.
4) refinish frame and engine. Depending on original condition, replace some gaskets, etc. Easy to do when engine is out.
5) make an initial parts order, stuff like steering/swingarm bearings, fork seals, wheel bearings, spokes, etc.
6) hopefully, by this time the hardware is back. install the engine and main wiring harness.
7) install suspension. rebuild wheels and install.

For the rest of the bike, just work from the inside out. I like to do sections at a time, so rebuild the wheels in one shot, refinish the bodywork at the same time, etc. Then new/refinished parts can go on the bike without the risk of being lost or damaged.

Keep a list handy of some major or discontinued parts you might need, so when you're browsing Ebay you can buy it.

For a restoration, the hardware is key. Nothing worse than a nice shiny bike with rusty ass bolts.

farnie wrote: A newbie to motorcycle work....

video -- courtest of racer 54

When started, the video may require about 30 seconds to load and start playing.
It's worth the wait!



Good Fortune!

Don't forget to get the correct Factory Service Manual for your bike. This is needed for all the specs and tension settings etc.

Old Man Rock wrote: No doubt Joe....

30 Year old KZ and don't know the history, only one way to really go in my worthless opinion....

Number 1 on the list: OEM SERVICE MANUAL... Study it!

Engine alone:
* Split cases for internal inspections. Replace as required.
Crankshaft/Clutch housing/basket/plates/transmission/gears/oil pump etc...
New clutch plate(s) & springs.

* Complete engine oil seal and gasket kit....

* Pistons & rings
New rings & cylinder hone at least.
Looking for extra umphka, 1075 piston kit, cylinder boring required.

* Camshafts:
Looking for extra umphka, .365 at least. GPZ1100 OEM cams .375 lift...
Cam degreeing required!

* Valve job: new valves, seals, guides.
Looking for extra umphka, possibly enlarged valves, at least port & polish.

* Timing chain, guides, rollers, idler gear.

Drive Train:
* New chain & sprockets (front & rear)

Carbs:
* Rebuild now doubt.
Looking for extra umphka, smoothbores to go with head P&P.

Frame: if not modding (example mono swing arm), powder coat or paint.

Electrical:
NOTE: Pending operating/charging conditions, test/confirm first.

* Possibly new wiring harness.
* Possibly new stator/Dynamo...
* Possibly new combo rectifier/regulator.

Ignition: coils, plug wire set, ignition plate:
* Dyna S set w/coils/plug wires at least.

Suspension:
* Steering, swing arm, wheel bearings etc...
* Most likely new rear shocks.
* Rebuilt front shocks.

Tank/Plastics:
* Tank rusted thus treatment.
* Paint tank & plastics.
* New petcock.

Brakes:
* Master cylinder clean/rebuilds.
* New pads

New Tires:

New throttle, clutch & brake cables:


Ok, I'm with Joe, my brain is now toasted!.... :laugh:

Post the project w/images... We're picture whores here!

Welcome to the OBSESSED insanity....

very good post, and i cannot agree more if its a bike you plan on keeping and really care about more than just a beater you HAVE to split the cases and know what you got. a true restoration is every nut,bolt,seal, and connector gone over and replaced or reconditioned to oem or better condition.

Farnie,

I see from your profile you have a three KZ650's you are working on for projects (one cafe the other bobber) and a parts bike. All 1978's. So it sounds like you know what you have to do. People here are very experienced and can give you much more detailed answers of what you will require. We can also point you the the appropriate build threads as needed. If you post pictures of all three bikes, you will be amazed how much information can be derived from a few pictures. And if you already have a ball park budget of what you intend to put into each bike then I'm sure people here can advice on that as well. But to give you an idea, my standard restoration (not a perfect restoration back to original showroom, but looks good and is road worthy) cost me about $1600 in parts and paint. All labor performed by so far with the exception of having new tires mounted. So there you go. You can easily do yours cheaper for each bike since you don't have to worry about expensive missing OEM body panels and parts, etc. Post some pictures of what you got, you will get lots of help for your list.