1983 KZ1000R2 Project

Warming it with a hair dryer will help you pull the wrinkles out (be careful !)

Nice!

Been there! A couple of hours in the sun will "settle" the cover nicely.

H.

rstnick wrote:

I've got to get some calipers to measure them, as my flat jaw calipers are of no use, as there's a lip the full thickness on the outter most edge.

 

Rob your "flat jaws" will get the job done if you use the below method (no need to buy additional calipers )

Wookie58 wrote:

rstnick wrote:

I've got to get some calipers to measure them, as my flat jaw calipers are of no use, as there's a lip the full thickness on the outter most edge.


 

Rob your "flat jaws" will get the job done if you use the below method (no need to buy additional calipers )

Thanks for the tip.
I actually thought of that, but did not think of using washers.
I had one magnet.
Was trying to find something else suitable.

It's okay though, as I've ordered new rotors for the front.
By eye and feel, I know the stock front rotors are not good.
I will measure them with some washers....

I picked up the tail and front fender from the painters today.
They look great
The tail had the stripes painted on, using the stock tail for reference.

 
 
 

I measured the rotors using some washers, and as suspected, they are at their limits; one @ 4.5mm, the other @ 4.14 mm.
4.5 mm is the minimum thickness.
 

Reassembling the forks.
The bottom cylinder fork has a round hole this square pyramid is supposed to hold.
Didn't work for me.

 
 

Also has the 12 point 22mm sized receiver.
I found an SAE sized nut that'd work, and a 3 foot threaded rod.
Had the nut welded on one end, and a foot cut off and welded on as a handle.
Worked well to torque the bottom Allen bolt.

 
 
 

One of the new front rotors came in.
From Australia.
Looks great.

 

 

The right front rotor came in.
The back side:
 
 

The front master cylinder I'm going to try:

 
 

The carbs came back from the vapour blaster:

 

One more bath in the Ultra Sonic Cleaner with solution, and rinse afterwards, then compressed air dried:

 
 

Got both forks reassembled, and remounted.
And a few more parts.

 

Front fender on.

 

I like how these brakes are designed:
Caliper mounts installed.

 

Then the brake pads:

 

Then the calipers:

 

New SS brake lines installed.

 

 

The master cylinder a buddy gave me turns out to be for a different set of handle bars.
The mounting angle is wrong.
Too bad I didn't notice this earlier.
What sized master cylinder would be needed for dual disk brakes?
Neither of these master cylinders has a size on them.

 

I got some of the carb parts installed, and the carbs put together again.
Wiating on a few more parts to finish them up.

 
 

 

I am pretty sure most Kawasakis use a 5/8 master for dual disc setups. As I am sure you know, a bunch of us are using 14mm master on our ZRXs with good results.

The old engine sprocket removed today.
I used the old chain and a couple of long bolts and nuts to assist.

 
 

New sprocket on, and chain, adjusted to proper slack.
Axle and torque link tightened up.
Clutch mechanism greased and new seal.
Clutch cable installed, and sprocket cover.
Left foot peg mount and pegs.
Gear shifter also installed.