Dutch 1977 Z1000 Build

750 R1,
I just cut off what I was thinking what looks good, almost broke my friends saw due to the glass fiber inside clogging up.
For mounting you can just use the clamp and the ring/gasket type of thing.
If you tighten the clamp the ring will expand and seal of the exhaust.
This only works if you have a snug fit with both pipes, mine did not.
I had to enlarge the muffler intake and coupling to the size of my pipe (63mm).
Then I welded a ring i made about 2 inch down the pipe which holds everything together.


Here you can see the ring still at the end but I moved it about 3cm inward.
(don't forget to place the ring with the 3 holes before you weld something like I did :S )

I found a picture with how it is now, top right corner.



It may be Chinese crap but it looks and sounds great :laugh:

First ride in 12 years for me and 3 years for this bike!



First I made a temporary bracket for the exhaust.


The fact that it is freezing and started to snow lightly did not stop me from my first ride in a long time.
The bike handles well (okay I did not past 45mph :lol: ).
The brakes are working and I did not have any problems (yet) with ground clearance.
Even on the speed bumps.
This saves me a lot of work on fork extension.
So on the positive:
Handling
Brakes
Electrical
Clutch
Sound :laugh:

On the negative:
Could not rev up full.(looks like it is starving and the fuel filters are not filling up fast enough)
When I stop nr3 carb is pissing fuel trough its overflow hose (float bowl??)
Some rattling form parts which I have to tighten or modify.
And strange leaking from the Body breather ( the Chinese hose has to be replaced) but it looks like a sort of foam.



But the bad part is still the oil leak from the head gasket.
Went by the Kawa dealer and if I have it fixed by him it cost me a lot of money.
He charges $200 for the gasket and O ring alone :sick:

So it is doing it myself and take a change of messing it up or find a fellow biker who can do it for me.

Eric

Hats off to you Eric,going out in this weather. I had to go out west of town (1/2 hour) to pick up my fork extensions.Not fun.
First thing I have to say is to stay away from official Kawasaki dealers .They are going to be the most expensive place to have work done.Find an independent workshop,itll be a lot cheaper.Also,buy the gasket yourself.
As for the filter,I was looking at a small one that I could hide under the tank but my local shop told me they are for scooters and dont allow enough fuel to pass through..I have one now about 5cm long and 3-4 cm wide.Of course I havent fitted in yet,What are you using?
How is your VHT paint coping with the leaking carb?

P.s. For the head gasket, with a workshop manual you should be able to manage it yourself.Youve gotten this far.

Hi David,
I was thinking the same about the dealer.
I guess I will be starting the job myself and "see where the ship strands" (dutch expression .
And when I get stuck I can always bring the pile of parts to someone else.

First I started out with larger fuel filters but with the same result now I have the same size as which where one the bike when I bought the bike, maybe there is some blockage in the petcock but when I open it while not connected fuel flows out quick.
For now I know the bike starts and runs, until the weather is nice outside I will be doing small cosmetic stuff inside.
Eric

congrats on the first ride going as well as it did. :evil:

as for the headgasket replacement.
as davido stated buying the gasket yourself and doing the work is going to be the cheapest solution.and well within your ability and plus you'll get to learn more about your street weapon :evil:
which is always cool.

leon

Wiers wrote: 750 R1,
I just cut off what I was thinking what looks good, almost broke my friends saw due to the glass fiber inside clogging up.
For mounting you can just use the clamp and the ring/gasket type of thing.
If you tighten the clamp the ring will expand and seal of the exhaust.
This only works if you have a snug fit with both pipes, mine did not.
I had to enlarge the muffler intake and coupling to the size of my pipe (63mm).
Then I welded a ring i made about 2 inch down the pipe which holds everything together.
Here you can see the ring still at the end but I moved it about 3cm inward.
(don't forget to place the ring with the 3 holes before you weld something like I did :S )

I found a picture with how it is now, top right corner.

It may be Chinese crap but it looks and sounds great :laugh:

I didn't mean it was Crap, just that it was cheap, I think its very good quality, just like you though, I think its a bit long. Thanks for the pics, My solution was a bit more complicated, I think you may have just saved me some time... , thanks....

Your fuel starvation could be the tank vent. I have two small inline filters with 33mm carbs. Plenty of flow.
Steve

Thanks guys for the encouragement, just the little push I need.
I am gonna do it myself

750R1,
You are right about the Chinese quality, expect what you pay for.
Until now it always exceeded my expectations and are happy with the shipping times.
Only one thing I ordered never arrived but that was sadly due to a cargo plane crash in Kyrgyzstan last month.
And I never know if I buy something from a "dealer" if it is the same stuff made in the same factory but then 10 times more expensive.
But to be sure the parts which are live savers like brakes etc. I buy in Europe or the US.

Steve,
I think you are right, it must be something else.
The filters I have now are the same size as which came of and the other ones I tried where larger and gave the same problem.
So it is either the petcock ore the fuel vent.
But what about the fuel dumping trough the overflow hose? Can that be a float valve or something like that?
Eric

Congrats on your bike....looking good. As far as the head leak pretty straight forward.
Manual best friend....

Took the carbs of and found that in nr3 one of the floaty things was bend upwards.
Bend it back equal with the other one and no more overflow:)
Did a few more test rides but same problem with "fuel starvation"?
Looked at my fuel filters and this is how it looks.


Not much fuel in there, also slow flow(more dripping)
If I take the tank of and open the petcock fuel streams out fast enough.

Before next ride I will put back old main jets(the plastic ones) and see with that does.
Also exhaust is very open, no DB killer and not welded on the joints.
So I will put in a DB killer to try and compensate for all the leaks in the exhaust department.
Now it is waiting for the weather to clear up and do some cosmetic stuff.

Eric

Check to see if the gas cap vent is clear.
Steve

What Steve says.Plus check the fuel tap and make sure thats ok. Also,try a bigger fuel filter and see how that goes,the one in the photo looks quite small( and Is it the right way around?).Another thing to think about,how dirty is the filter? If its clean (and you have been running the bike) then do you really need it??