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73 Resto - "Now this is not the end. It is not even...

Posted: Wed Nov 05, 2008 9:55 pm
Author: MaineKZ
...the beginning of the end. But it is, perhaps, the end of the beginning."

Well it's begun. 14 months after buying the bike, building and fitting out a resto shed, and chosing a suitable bike lift, I turned my first wrench on Sat Oct 25th.

Job no.1, get the hulking great thing up onto what looks like quite a dainty lift - the Original Red - chosen because, with only an 8' x 8' area to play with, I needed something compact with maximum access. I roped in local 73 Guru Steve Thomas and she went up without a struggle. The main lift is via the footrest mounts - the stock pivoting items were replaced by 'solid' alternatives which worked out just fine.

I would recommend this lift without reservation, but I'd suggest that any big torque work is done BEFORE you lift - Front sprocket being a good example!

I'll let the pics do the talking but I'm pleased to say she's now stripped and ready for engine removal and, as yet, I haven't had to scrap with any fasteners - nothing's stripped snapped or sheared. Guess that's one advantage of buying a bike imported from a salt free state with 13K on the clock!

Next step will be full engine strip. Dogz will inspect internals for me, casings will go to Doug Cox for blasting and 2 pack finishing giving as near an original finish as possible.

Frame and ancilliaries will be blasted then I'll spray with epoxy paint from Frosts. I've tried it and it comes out looking very like the original cellulose finish - providing you don't spoon it on! Also benefits from using a black undercoat - so it even looks like the original when it gets chipped!

More photos as I go along....

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A few pics just to give an idea of condition. Basically it all there, it just a bit tired:



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The engine cam apart nicely and the internals look good. Just hoping Dogz agrees with me! Only serious damage I've come across is the butchered starter motor casing near the oil pressure switch (final pic). No idea why this was done - can only think some lazy git needed access. The damage is clearly hacksaw cuts, not fractures. Anyhow, it'll weld up just fine. The Oil pressure switch lead held on by a cable tie did make me chuckle!



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Posted: Thu Nov 06, 2008 1:13 pm
Author: Pasc
Looking forward to following this one Mr Maine.
Keep the pics coming.

Posted: Thu Nov 06, 2008 1:54 pm
Author: Steve S
Superb pictures,great for reference,good luck with the rebuild we are all going to enjoy watching,keep the photos coming :D :shock:

Posted: Thu Nov 06, 2008 6:53 pm
Author: bunnysZ
about bloody time too,
you missed a whole season of wonderful sunny weather riding ,.... :D
.... expect it to be ready for april kawasaki day at the ACE or the latest yorks rally end of may.... no excuses... :twisted:
pm sent chris

Posted: Thu Nov 06, 2008 8:14 pm
Author: GUYZED
What a great project - wouldn't mind doing something like that myself

Doug Cox did the blasting on my engine - brilliant job as all ways :up

keep the pics coming

Posted: Sat Nov 08, 2008 7:43 pm
Author: Davy Doherty
looking good Main please keep us up to date..

Chapter Deux - Engine Strip

Posted: Mon Nov 10, 2008 8:19 pm
Author: MaineKZ
Just sat down with a nice glass of absynth after finishing the engine strip.
Huge thanks to Dogz who whizzed over to help with the lift out. He also produced a clear bill of health for the internals - almost no discernable wear to bores, pistons, cams or valves. She's a good'un - thank Gawd!
Pics will do the talking but, once again, I didn't meet any real resistance - apart from the clutch hub bolt which seems to be torqued up tighter than the front sprocket! It'll be OK though - now the gearbox is apart I'll be able to get a better grip to get it undone.

First off some pics of the garden trolley I adapted to hold the motor during the strip. Do not adjust your set - the engine needs to be upside down to split the crankcases.

The timber mounts can be positioned wherever on the timber bearers so I'll be using it again for re-assembly.

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Next few pics show me cracking open sump then then big one - crankcase split. Dear MR Kawa provides 3 threaded holes in the lower half - you wind in 3 x M8 bolts and these bear against the upper half and force the two halves apart. With a liberal amount of tapping round the joint with a timber mallet the joint finally gave way. Little nerve-racking though! Recommend you go REEEALLY steady when winding the bolts down.


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Once the cases have been split, gearbox and crank came out with ease.
Final shot is of that legendary crank - now that's what I call over-engineering!

Next step will be a massive de-dreasing session, preparing casings to be shipped off for blasting and re-finishing.

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Z1

Posted: Tue Nov 11, 2008 10:01 am
Author: justin taylor
Chris,is this to keep or sell when finished?JT

Posted: Wed Nov 12, 2008 7:07 pm
Author: MaineKZ
Hi J

This one's for keeps - probably. Nowhere to go from a 73 I reckon.

You fixed up with a Zed yet?

Posted: Thu Nov 13, 2008 12:38 am
Author: Keefleaf
72 ?

Posted: Thu Nov 13, 2008 8:39 am
Author: MaineKZ
Keefleaf wrote:72 ?


there's always one :roll: :D

Posted: Fri Nov 14, 2008 11:24 am
Author: Keefleaf
It`s a tough job but somebody has to do it :D
Keep the pictures coming,looking good.

Posted: Fri Nov 14, 2008 11:40 am
Author: tlc
It amazes me that the engine internals look so good considering its age !

Posted: Fri Nov 14, 2008 11:47 am
Author: Pasc
MaineKZ wrote:Hi J

This one's for keeps - probably. Nowhere to go from a 73 I reckon.


Ahem, z1000R :lol:

Posted: Fri Nov 14, 2008 2:48 pm
Author: MaineKZ
[/quote]
Ahem, z1000R :lol:[/quote]

Post '75. Automatically excluded from the shortlist I'm afraid.

Them's the rules :D