TOPIC:

Well, 2 hours after starting the teardown, this is what I have so far to work with. I have the engine to pull and the front fork to dismantle and the rear tire/swingarm to remove. Then remove all of the cracked rubber stuff and start cleaning the frame. Should I keep the frame black, or go to a gray or silver? I am not sure what the final color will be yet.

A few random hints:
You have to remove the rear wheel to get the airbox out.
That motor is heavy! ~180 lbs.
When you remove the front fork ball bearings are going to go everywhere, replace them with tapered bearings.
Plan on replacing the swingarm bearings, seems like no one ever greases it.
Upgrade to dual front disk using 650/1000 rotors and calipers, the rotors off dual disk bikes are thinner.
Most of the rubber parts are still available from Kawasaki.
Your front master cylinder is already 5/8" but rebuild kits are not available.
My 750 project is going to be black with silver frame, so don't do that
The brake pedal can be a real bear to remove.

I have done several 750 twins, so if you have any questions feel free to ask

Thanks for the tips. I have already had the motor out before (did it without help and carried it around, I didn't think it was THAT heavy (maybe I'm just stronger than I thought!)), replaced rings and several valves (don't ask).

Yeah, the air box will NOT come out the side of the frame, I tried.

Already switched the stem bearings to tapered, and planned on ordering swingarm bearings.

I think I'm using Fleet Farm Implement paint for everything. I should be able to get good results, and a pretty durable finish at the same time. Cheap too, about $8 a quart, if I remember right!

I just swapped engines in a 900 by myself. It was harder to pull the old engine as I didn't do any disassembly and I assembled the new engine in the frame. The 900 engine is about 225 lbs with all the stuff on it...

In any case, couple of hints... listen to folks who tell you to replace all bearings. Use roller bearings in steering stem, swingarm and use NEW wheel bearings. It makes the bike handle so much better! The bearings are relatively cheap! Second tip is to take off the wiring harness and unwrap it and look for surprises underneath! Clean it up and make sure everything is connected as it should be and no bare wires and then rewrap it in electrical tape. I know it is a chore but having a reliable bike makes life a lot more fun! Clean the connectors good and pack with dielectic grease. As you finish sections of the clean up of the wires, wrap a little tape to keep that section together and then do a final wrap over the whole thing.

Well, after a couple more hours...

have done several 750 twins, so if you have any questions feel free to ask

Are there two sets of tapered bearings there? What about washers and so forth, also, do you know of anything I may need to really concentrate on. I have a 77 twin. Thanks alot.......................