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TOPIC: Retroactive KZ750E Project Thread

Retroactive KZ750E Project Thread 13 Jan 2017 07:37 #752062

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Even though this bike is finished now I'm going to put up this thread for reference purposes just in case it could help someone else working on their bike. I'm not a professional restoration guy, just someone that has learned a lot by making mistakes doing. Remember, it's only a "mistake" if you do something wrong TWICE.

I always loved the 750E and GPz550/750 bikes. All my early years of riding was done on smaller bikes (400/550's) so to me a 750 IS a big bike. At any rate, got a tip from a friend about the availability of this bike so went for a look. It was only 10 min's away so I couldn't resist. One of those "ran when parked" bikes, only this thing was "parked" outside for the last five years. I paid too much ($700), but it did come with two exhaust systems, one of which was a Mac header that was easily sold to bring down the effective purchase price. Here we go...










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Retroactive KZ750E Project Thread 13 Jan 2017 07:38 #752063

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Retroactive KZ750E Project Thread 13 Jan 2017 07:43 #752064

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Excepting for some crappy alarm that was installed in the tail section the bike was pretty much unmolested. Bad news is that it was corroded pretty badly. Carbs completely frozen, rear master dry and stuck, brakes frozen, etc.

I paid too much but oh well...



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Retroactive KZ750E Project Thread 13 Jan 2017 07:46 #752065

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Good news is that the inside of the engine looked clean.







Found a friend keeping an eye on the bike for me. These little buggers are everywhere in my area and shop. Have to pay attention.




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Retroactive KZ750E Project Thread 13 Jan 2017 07:48 #752066

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The webs are just like that photo shows in that they are very random, messy, disorganized. Almost looks like the typical abandoned web after a few weeks. These ladies are not good housekeepers.



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Retroactive KZ750E Project Thread 13 Jan 2017 07:50 #752067

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Degreased and cleaned for blasting...









Something to do in the evenings...



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Retroactive KZ750E Project Thread 13 Jan 2017 07:54 #752068

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Pistons looked good, but cylinders look a little funny. Borrowed a bore gauge from work and measured them. Not thrilled with the numbers but usable. Going to bottle brush hone and install new OEM rings.




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Retroactive KZ750E Project Thread 13 Jan 2017 07:56 #752069

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Blasting, blasting, and even more blasting...





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Retroactive KZ750E Project Thread 13 Jan 2017 07:58 #752070

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Retroactive KZ750E Project Thread 13 Jan 2017 08:01 #752071

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Transtar Epoxy Primer.

Finally found a good use for the ironing board...

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Retroactive KZ750E Project Thread 13 Jan 2017 08:19 #752073

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Gloss top coat was Nason urethane. Fleet paint. Wonderful stuff. Amazing really. Flows out amazingly well and you have to hamfist the gun to create runs. Shot the paint with a Sata minijet spray gun. The semi-gloss paint was Por-15 Chassis Kote. Looks good but really sucky to spray. The Nason spoiled me and the Por-15 punished me...



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Retroactive KZ750E Project Thread 13 Jan 2017 09:41 #752077

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Doing the frame was an exercise in masochism. There was a fair bit of surface rust, particularly around the tabs and brackets, and underneath the steering head area.

Paint stripper, the good stuff that washes off with mineral spirits, was first. Interestingly, Kawasaki used some sort of yellow primer on the lower half of the frame, but no primer that I could see on the top half.












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Retroactive KZ750E Project Thread 13 Jan 2017 09:44 #752078

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Next was Kleenstrip Metal Prep as sold by Home Depot to eat off some of the rust.

Phosphate sauce doing it's thing. About 90% of the rust is gone. After a good water rinse my leaf blower was used for drying.








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Retroactive KZ750E Project Thread 13 Jan 2017 09:47 #752079

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A wire wheel was next followed by coal slag blasting. The blasting was focused in the areas where there was old remnant paint and rust, and to rough up the metal for paint. In the past I used to use "play sand" for blasting, but a friend pointed out that the silica was bad for the lungs so coal slag was used hereafter.






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Retroactive KZ750E Project Thread 13 Jan 2017 09:53 #752081

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Transtar epoxy primer followed by Nason urethene...












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Retroactive KZ750E Project Thread 13 Jan 2017 09:57 #752082

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Wheels, brake calipers, and handlebars were done in Gun Kote for the extra durable protection.

These parts were supposed to be "satin black" but there isn't much satin that I can see. They weren't bad to the point that I was going to redo them though.











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Retroactive KZ750E Project Thread 13 Jan 2017 10:01 #752084

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Some photos of the first set of Keihin's that were done. I ran these for a while and then did an even better set that are on the bike now.






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Retroactive KZ750E Project Thread 13 Jan 2017 10:03 #752085

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I love what you did with your KZ750E. I followed your build for a long time. Congrats on making BOTM!!!! I built a KZ750E back in the early 80's. I used many of the same parts you did. The GPz feetpegs, and the oil cooler were the same exact parts that I used on my E model. Your build brought back more than a few memories.

I road raced mine in a few WERA endurance races back then. I parked it when the Honda Interceptor came out in '83. After that it became my primary streetbike. Gold wheels were my trademark back then as you can see in the one photo.



1972 H2 750 Cafe Racer built in 1974.
1976 KH400 Production Road Racer.
1979 Kz1000A3 Old AMA/WERA Superbike.
1986 RG500G 2 stroke terror.
1986 GSXR750RG The one with the clutch that rattles!

Up in the hills near Prescott, Az.
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Retroactive KZ750E Project Thread 13 Jan 2017 10:03 #752086

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Hand controls were heavily weathered so bought a couple better units for parts off ebay. Took them all apart and cleaned/greased in innards. Fixed a broken wire here and there too. Good fun and nice change of pace compared to all the painting and messy work.








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Retroactive KZ750E Project Thread 13 Jan 2017 10:08 #752087

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Petcock was next...

Bead blasted the body and replated the steel parts. Fortunately, Kawasaki still sells the internal guts for these things.






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