1983 KZ1000R2 Project

Both tank badges had damage to them:

 
 

I replaced them with new ones.
The old screws were sprayed with penetrating oil a few weeks back, and came out easily.

   
 
 

The rear tail badge had some srapes as well, but some black touch up paint, and it should be okay:

 

Bled the rear brake today.
It wasn't going well, taking too long, pumping pumping, and no fluid coming out the other end.
I tried using the brake vacuum pump that failed to work the last time I tried using it.
Surprisingly, it built up vacuum, and was able to pull brake fluid through!
Now have good brake pedal feel, and the rear brake works!

 

Used some double sided tape to reattach the tail badge.

 

New float valves & seats came in.
I reassembled the rest of the carbs.
They are now ready to go back on.
I'm just waiting on new carb holders.

 
 

The battery is not acting right.
It's a new Yuasa I bought a few months back.
I filled it with acid, and charged it with my low Amp charger.
Seemed okay in the biginning, but now the trickle charger doesn't go to green when hooked up.
I put my low Amp charger on it for some hours during the day, but it seemed to get too hot, so stopped.
Voltage was about 12.2 volts to start, and didn't go up very much.

 
 

Rob, really nice work, I'm always impressed and the rate you crank out work. (AJ from the KZ650 forum  )

Thanks AJ.

The carbs got reinstalled.
I used the carb holders that came on the bike, as they were soft and not cracked.
I had ordered two different new sets of carbs holders, but both sets only had 30mm holes in them where the ones on the bike are 34mm.
The carbs are 34mm, so I'm at a loss why the two sets I ordered are smaller.
Anyways, carbs are back on.
Fairly easy with new air box boots.
I did think to install the throttle cable first, but should have also installed the fuel line and vent hoses, as they were a pain to get on afterwards.

 

I bought a new reproduction rear fender.
It's a Euro version, much longer than what was on there:

 
 
 

Reinstalled the fairing too.

 

I moved the bikes around the workshop, in antissipation of getting the project off the lift soon.
A new master cylinder for the front should be here any day.
'That should help when unloading the bike.
The exhaust needs to go on soon too.
Then it's a test fire. 
500+ lbs of bike, and a lift that doesn't move around easy, makes for some heavy pushing.
Managed to get the lift to a better off loading position.

 
 

Father and Son.

 

I painted the silver washers I used on the windshield, black.
Looks much better.
I've got one silver screw holding the windshield on my ZRX. It really bugs a friend. 

 

The front Master cylinder I ordered came in.
Installed and bled.
We have a front brake!

   

 

Spent the day at the Canadian Motorsport Park for the Vintage Road Race Association (VRRA) event.
Some friends are racing, and the VRRA had a Motorcycle Show, and Swap Meet.

 
 
 
 
 

When I got home, my Son in Law was on the porch.
I asked if he could help me get the 1000R off the lift.

 

Now I can install the exhaust, and finish up a few other things.
Then a test fire.

The front brakes work, as does the front suspension. 

I didn't like the caps on the carbs for the vacuum connections.
So I ordered some 650 caps, on the right.

 

Got the Hindle exhaust on today, as well as the gas tank all hooked up.

 
 

The exhaust sealant on the slip joints needs 24 hours to dry.

 

So no start up today.

 

Got home from work and brought the 1000R outdoors.
I wanted to add some gas, and try to start her.
Outdoors, in case she leaks, which she did.
Bowl #3 was leaking.
Tighten up the drain screw, and all the others, and no more leaks. 

Turn her on, try the start button. Nothing. 
She doesn't turn over. 

A quick few checks; fuses, wires. Nothing.
Back into the workshop, as Dinner time is approaching.

 
 

After dinner, off comes the gas tank.
Start checking circuits with my multi-meter.
Clutch lockout switch - OK.
Starter Soleniod - rotates the starter when I short out the two large connections.
Starter button - Does NOT make connection/close circuit, when starter button is pushed in.

I disassembled the right handle bar switch, cleaned the starter button pieces, taking the switch completely apart.
The contact areas were black so cleaned them up lightly with a file, then some spray contact cleaner and a rage and cleaned all the bits.
Reassembled and the circuit works with the tester.
Don't have the gas tank on, but try to fire her up.

She started for a few seconds!
Stunk up the workshop.
Too late to fire her up now.
Tomorrow after work I will try again.

 

Tried today to start her again.
No choke this time.

She started.
Sounds terrible.
The revs are hanging up, lots of smoke everywhere.
But she started!
After 15 + years. 

youtube.com/shorts/8xr6H1Why8Q?feature=share

Yay, happy days 🍻
One of my favourite steps after so much work has gone into it.
Rich.

This morning I started her up again.
The revs are really hanging up, around 4000 RPMs.
Smoke coming up from the front of the engine, I think from the slip joints in the exhaust at the head.

youtube.com/shorts/WiqLtKpqSrs?feature=share

Afterwards, the oil looked too milky for my liking, so I changed the oil and filter.
Off comes the exhaust again to do so.
Installation was much easier this time.

 
 
 


I had the Pilot screws set at two turns out.
As that's what I thought I read.
But looking at the Factory Service Manual, it states 1 1/4 turns out for the Pilot srcews.
So I readjusted them to 1 1/4.

With new sealant on the exhaust joints, I will wait until tomorrow to start her again...