1983 KZ1000R2 Project

Awesome news Rob, enjoy

Remember, Rob - test ride repeatedly!

I got her out for her first, and second, test rides today! 

First ride just around the block, in first and second gear.
The RPMs are hanging up a little still, making shifting a little tricky.
The gear shifter pivot also has a lot of play, making shifting sloppy.
Something I will try to address over the coming Winter.
I made it home okay.

 
 
 

The valve cover was leaking oil.
I could see bubbles coming out at the seam.
I hadn't checked the valve cover bolts, and sure enough they were loose.

Tightened up, and a second test ride.
This time a little further.
Into 3rd gear, and up to 100 KPH.
She rides well.
Brakes work well, the front suspension well, and surprisingly the 43 year old rear shocks took the bumps well.

 
 

Moving her around in the shop, she did not feel good: the handle bar position, or the new tires gripping the foor.
Always felt a little heavy steering her around the shop.
Out on the road she felt great.
Handled well.


 

Great news Rob, and looking great.

Well it was great to be able to get her out for a few short rides.
Now though, there will be more to take care of over the coming Winter.

The rear turn signal and tail light mount I noticed was rusty, so I took it off to clean and paint.

 
 

Same with the coil mounting brackets, rusty.
They were both broken at one mounting point I found out, once removed.

 

The rear turn signals were not stock.
I bought some new ones.
Boy do they stick out far, and one needs a little adjustment.

 

Have ordered more parts.
Postal Strike happening now in Canada, so they will take some time to arrive...

 

 
 

She looks really nice now Rob, great work

Wow, the bike looks brand new. Excellent job! 

I did manage just over 20 KMs on my test rides.

 

Now that October has arrived, there's no rush to be getting her on the road.
There are more items that need checking and going over.

When installing the new rear turn signals, I noticed the left one was further forward than the right, and the taillight was not straight, compared to the tail.

 

So some adjustments, and they are looking better.

 

The aftermarket dual horns had a relay wired in, under the seat.
It got it's power from the starter solenoid, so the horn would work with the bike's Ignition On or Off.
I did not like this.
And I removed the large horns, and went back to two smaller stock looking horns.
I then removed the horn relay wiring, and wired the horns back to stock.

   


Tested the horns.
All is good, they only work when the key is on now.
Rewrapped the wiring loom.
Soon will be checking the Valve Clearances.
The red zip ties are temporoay, holding the coil wires.



Removing the extra wiring has freed up space under the seat, allowing the tool tray to sit better.

 

Checked the Valve clearances, bought needed shims, and made adjustments.
Shim under bucket for an '84 GPz1100 engine.
Same shims used in my '78 KZ650.

 

It was brought to my attention that the cam sprockets have been slotted, to degree the cams.

 
 

All ready to close up.
New cam end plugs and gasket, after the mating surfaces have been prepped.

 

Bought new Dynatek coils and wires for her.
will install them soon.

 

 
 

 

 I got a package in from the UK.

 

A new fork brace for the project:

 

Going to make these skinny legs a little more stabil.

 
 
 

Also got the Dynatek coils test fitted, and the spark plug wires made up.
At first I thought the coils were sticking out too far, and would interfere with the gas tank, but a test fit eased my mind.

 
 

The wires then could be made up.
I was a little generous on the length of the wires.

 
 

 

More parts arrived today.
Some new exhaust flange nuts, exhaust gaskets and a throttle cable.
Only one cable on this model.

 

Also the shocks I ordered came in.