'76 KZ900 (ZRX1200R) Build

The trimmed down fender looks much better. I bet you are getting antsy to get this project done . By the way, I finally got a Connie 1400.
Wayne

So I just tore the bike into little, bitty pieces. It is off to the powdercoater in the coming week or two. I still need to decide what color I am going to PC it...... I guess I can procrastinate only up until the loading dock lol.....

You're right Wayne, needs to get done! I am trying not to bring home any more projects until this is done. Paint and powdercoat are getting me close. Engine work will be the last piece. If I can get the $$$$ together, the engine work should go quickly.

Congrats on the C14! You'll love it! With the mods to mine, it is the perfect long distance canyon carver.....too bad their are boring roads here!

Cory

Hey Cory,

Just spent the last day and a half reading through this since page 1 between work and family time. Gotta say this is a tremendous build and I love seeing you still working on it and getting close to wrapping it up today! Too often we see projects fizzle out half way through to never hear back from again. You've put a lot of time ,sweat, blood, tears and money into this and the results speak for themselves! There are so many things that you've done that I would love to be able to do myself but without access to any type of machining equipment such as a lathe or mill that just is out of the question for now.

Really appreciate you sharing and doing such a great job explaining why you made certain decisions and how you solved some really complex issues, learned a ton by reading and I am not new to building one off stuff but I come from the car world and trying to transition to bikes now. Not a TON cheaper but since my wife and I are still pretty young (28 in March for me and May for my wife) plus a 3 year old just starting preschool yesterday, money is not leaking out of our ears so even small things are hard. Miss wrenching on the cars but moving over to bikes has been scratching that itch.

Thanks again and keep up the amazing work Cory, way way kewl!

Brett

So it begins..... I have taken a quick swag years ago at the inside of this tank and used a varnish remover product. It did remove quite a bit, but there is still crystallized varnish present. Came by a thread that talked about different chemical methods of removing the varnish and rust. One of the recipes to try is this...

So first trying it. I used boiling hot water and first rinse showed some promise. Second batch I am letting sit over night.

I also have a gallon of Acetone if I need to and I can try some toilet cleaner for any rust. I do not want to have to go through the hassle lining the tank and from what I see, I don't think I'll have to. I have a ton of chrome ball bearings I bought for shaking later as well....

So while I am waiting, time to pull the engine apart and get some of the pieces ready to send to Joe at Pitstop. Going to drive down and deliver them myself.

First issue I had when I originally got the bike was the PO stripped one of the cam cover bosses. Going to have to invest in a Helicoil kit.... The other issue is while trying to use my JIS bit and electric impact, I stripped out the head of the forward chain guide screw and left me with this....

Luckily while digging around in my tools, found a good, sharp square drive bit the I could tap into the center with a hammer and use the impact to back it out after application of my propane torch to the top of the screw and sides of the boss. Crisis averted..... Safe to say all these JIS screws are getting replaced with socket cap screws upon reassembly. That is it for now, more to come.

Cory

its better to use sharp stuff instead of ball bearings. something like drywall screws. they dig into the crud better. what are your plans for the motor?

If you replace the cam guide screw with a socket cap screw the cam chain will hit it.

I doubt it, the chain goes on the inside and down past the screw just on the guide. The guide only sees wear when the chain is too loose.
Steve

DoctoRot wrote: its better to use sharp stuff instead of ball bearings. something like drywall screws. they dig into the crud better. what are your plans for the motor?

Understood. Since the varnish isn't that bad after the varnish remover a couple years ago, I didn't think is was necessary to go to screws & nuts.....

Cory

peter1958 wrote: If you replace the cam guide screw with a socket cap screw the cam chain will hit it.

As stated the screw is back pretty far, but either way I wouldn't probable use a standard socket head, but a button head Allen.

Cory

well some one on here had that problem before , Might have been the mod

I've had them destroyed. Just the lower pin left and the screw on top. At no time did the screw get nicked. Button heads are a good choice. I used them on my Dyna coils. Nice and flat.
Steve

Yeah, I've had to use button heads myself. They have a much lower profile.