GPz 750 project

[andym]

OK I figured it was time to open a project thread... I know there are a lot of people out there that do this kind of thing for a job/hobby/fun, I am doing it for experience... and to see if I can get it back together.

Please remember this is my first attempt at anything like this, so if you can give me any pointers on where I might be going wrong, then let me know

OK I bought the bike as a cat c for £250. The original intention was to strip everything down to individual parts and see if I could rebuild it again. When I bought it, it looked a bit like this:

https://img.photobucket.com/albums/v320/andy36586/GPz750/JA4.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/JA5.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/JA3.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/JA2.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/JA1.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/JA6.jpg

At this point I did see it running, so I decided not to do too much to the engine, since everything looked a bit tired and had a couple of other issues to sort I figured it would just need a bit of paint and a few hours work, so I took the panels and a couple of other bits off:

https://img.photobucket.com/albums/v320/andy36586/GPz750/start5.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/start6.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/start2.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/start4.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/start1.jpg

Unfortunately I don't have the next photos in the sequence uploaded yet so I'll get that done later and post the next 2-3 updates then it should be up to now.

[andym]

OK edited the photos, uploaded them so I'll try to get as much put on here as I can

As you might be able to tell I tried a bit of engine laquer on the engine to see what would happen to it when it warmed up, and I wanted to check everything worked as it should since this was my first non-air-cooled engine... so this was the set up I used:

https://img.photobucket.com/albums/v320/andy36586/GPz750/Temptanksetup.jpg

Later that night I ran the bike for about 20 minutes (after getting my new dials (whatever the correct name for them is), and watched the temperature go up and up with no fan kicking in, later I checked the back of the fan and found out that there was just a length of cable leading to no where. I'd also found out that my temporary ignition switch wouldn't cut the engine when I wanted it to.

During one of my tests the engine started racing and I flicked the switch and nothing happened... in a panic I made sure the side stand was down and forced it into gear (has clutch issues too).

I put an end to all testing after that and waited for a couple more bits and pieces to be delivered.

One night after yet another disagreement with the family I figured I'd spend a bit more time on the bike (by this point I believe I had been banned), so figured to avoid temptation I would strip a couple of parts off the bike... as was the original plan.... it was amazing how quickly it all fell apart:

https://img.photobucket.com/albums/v320/andy36586/GPz750/morebikestripped.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/engineinframe.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/bikestripped.jpg

Less than 2 hours later this is where I was up to.

Then over the next few weeks I started cleaning, sanding and painting (oh and filling):

https://img.photobucket.com/albums/v320/andy36586/GPz750/PetrolTankfilled.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Forksandparts.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Carbscleaned.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Alternatorandstarter.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Enginefullypainted.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/enginetoppainted.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/framerough.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/framepainted.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Junk01.jpg

After a disagreement for the last time I figured it was time to get my bike out of the garage one way or the other... so it took several trips, damn near killed me moving the frame then a lot of the parts round to my flat in 1 day, but I still managed it....

I would just like to say a very big thank you to Cyclone200 for the camera, the following pictures wouldn't be possible without it

https://img.photobucket.com/albums/v320/andy36586/GPz750/randombitsspreadout.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Randombits.jpg

Unfortunately the only part I couldn't manage myself was the engine, which also happened to be the part that I needed to start rebuilding everything, so I had a friend deliver it and got to work:

https://img.photobucket.com/albums/v320/andy36586/GPz750/enginefitted2.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Forksenginefitted.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Frontwheelrefitted4.jpg

This was what I had to do to get the tops back on the forks: And before anyone points out, I know the wheel was round the wrong way, I had it tied to the frame for the extra weight and the petrol tank was almost full of water too
https://img.photobucket.com/albums/v320/andy36586/GPz750/Balanced.jpg

Making sure the tank would fit with the new air filters:

https://img.photobucket.com/albums/v320/andy36586/GPz750/Tankinplace3.jpg

And how it looks now: (again I'd just like to point out the condition of the chain there... a quick rince with white spirit then left in a oil soaked cloth in a bag with more oil poured in and left for a couple of months.... that's what came out at the end of it)

https://img.photobucket.com/albums/v320/andy36586/GPz750/sideprofile.jpg

I feel that there won't be a lot of differences in pictures from this point, because it is mainly sorting out the problems that were originally on the bike....

Anyway I'll hopefully keep this thread updated with the progress

[Sako]

look forward to the updates! good luck.

[Stonefly]

Great stuff Andy, keep up the good work.
Capital effort under difficult circumstances. I will be watching the thread closely.
____________________
Current......Kawasaki ZZR1200 C2H and Kawasaki ZZR600 E7
Previous....Yamaha FS1E, Honda SS50, Suzuki AP50, BSA Bantam D14, Honda CD175, Honda CB250N, Kawasaki Z250A3, Yamaha RD250E, Kawasaki Z400, Kawasaki Z500, Kawasaki GPz550, Honda NTV600, Kawasaki GT750, Kawasaki Z1000R, Kawasaki GPX250

[MarJay]

I hope you're planning to fit the darth vader style fairing...
____________________
British beauty: Triumph Street Triple R; Loony stroker: KR1S; Track fun: GSXR750 L1; Commuter Missile: GSX-S1000F; Cheap project: CBR900RR FireBlade
Remember kids, bikes aren't like lego. You can't easily take a part from one bike and then fit it to another.

[andym]

Since it was a nice day I decided to spend most of it outside working on the bike, unfortunately since most of the parts are back in place there won't be a lot of visible changes, but here's a few more pictures of stuff.

Today I rebuilt the front brakes, tested them with the scooter M/C, it works to some degree, but I noticed that the calipers are still moving when I pull the lever, so I'll need to address that tomorrow, but I done a fair amount with the wiring loom... which even with it looking like this:

https://img.photobucket.com/albums/v320/andy36586/GPz750/Wirejungle1.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Wirejungle2.jpg

I did manage to get ignition lights:
https://img.photobucket.com/albums/v320/andy36586/GPz750/Volts.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Ignitionlights.jpg
Also tested the start button and it did turn over the first time I pressed it... but after trying to get the headlights working (tail lights work, front brake switch works, although 1 light is coming on dim so I'll need to mess around with that I think), now it doesn't want to turn over any more.

Hopefully it'll be a nice day tomorrow and I can get back to it and sort all the electrical stuff out.

I did try putting on the side panel to see what it looks like, because of the air filters I've had to cut a small piece from inside the panel, but with it in place for some reason I don't like it. I might have to find a way to protect everything and leave the side panels off... but I'll see

This is how I left it for today:

https://img.photobucket.com/albums/v320/andy36586/GPz750/Sidevewwithpanel.jpg

[anthony_r6]

I saw all the pieces on the floor and thought "like hell he's going to get that back together" but you proved me wrong I wish I had space to do something like this.
____________________
Ted : "Maybe he's agoraphobic."
Dougal : "Jack scared of fighting? I don't think so, Ted."

[andym]

[temeluchus]

I had a GPz750R, good well mannered bike with decent power and surprisingly lithe handling. Has the distinction of being the only bike I got caught by a speed camera on.
____________________
Some shite cruiser. Now with guns and FREEDOM!

[andym]

[andym]

Not really got any more pictures to add to this at the moment, but I will add another link to the youtube videos of it first starting (with the convenient use of the vacuum hose stuck in the breather hose on the carb ), and it seeming to run fine on its own (I should point out that on the first attempt there was oil pissing out the top of the carrier pipe thing, which was sorted for the second video, but noticed the water pipe on the side has a leak....

https://www.youtube.com/watch?v=AYKujgcphCI&feature=g-upl (still trying to figure out what said 'miiiimaaaay' at 23 seconds)

https://www.youtube.com/watch?v=jqSeq0b_u7o&feature=relmfu (the hissing sound is the air being drawn in, sounds worse than the video shows)

Anyway, today I decided I would try to get it rolling as there wasn't any gear lever on it, and the last time I tried as soon as I put it in gear it cut out instantly. But today with a few presses of the clutch before trying to put it in gear it seemed to work. Unfortunately I had wanted to start working on more electrics, but it started raining every few minutes so I had to cover everything up and call it quits for today. Depending on the weather tomorrow I might have a go at getting some nuts and bolts back in place, start on the electrics properly and get all the lights working (and hopefully find the earthing fault for the brake lights).

Tonight I'm going to try getting the petrol tank dried out (which since it's all going to need repainting anyway I might just blast it with the heat gun.... I might actually remove the petrol first too), and since the weather looks like it's going to be a bit mixed over the next couple of days I might do a better job of filling the petrol tank.

Anyway, if anyone can help with the following things:
Master brake cylinder (using a temp 50cc M/C at the moment)
Rear plastics
Some method of holding the headlights on that will pass it's MOT
Some thin metal strips strong enough to hold the dials in place (at the moment they are too close to the ignition barrel)
Sensible methods of holding the carbs up as they are being held by the engine at the moment.

Any help appreciated

[UnspeedySam]

Nice going. Looks like it'll be a fun bike to ride. With my Rxs, earthing is the key to good (well everything is relative) electrics.

I've got a zzr600 mc that I scrapped because it had hacksaw marks in it (previous owner removing seized screws) but it works perfectly fine. Pm me your address if you want.
____________________
Riding: BMW R1150RT `02 bought mildly crashed
Fixing: Also the BMW as I get less broken bits
Gone: ZZR600 '00, TRX850 '97, RXS100 '93, JS125-6B '07, BMW R1100RS '93, Kawasaki ZX-6R-J2 '01, Honda Bros NT400 NC25 '88

[andym]

It's been a while since I've updated this, so here we go.

I managed to get me some bits and pieces from ebay quite cheap (main thing being the rear fairing, which when I put the side panels on it didn't look right, now that i have the end piece it looks much better).

Anyway I'd been mucking about with the can of paint that I had kicking about (until I had the money to buy more), decided to see what would happen if I took out the orange peel effect and polished it (this is matt black paint remember):

https://img.photobucket.com/albums/v320/andy36586/GPz750/Paintsandtest1.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Paintpolishtest2.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Paintpolishtest1.jpg
This was only a couple of thin coats so that's why the primer was showing through in places.
I should point out I was doing this spraying in my livingroom, but gave up when I started getting a bit light headed

Since it was a nice sunny day (although a bit too windy but still went for it anyhoo), I decided I'd get the panels done since my cheap ebay paint arrived yesterday:

https://img.photobucket.com/albums/v320/andy36586/GPz750/Panelsreadyforpaint1.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Painted2coats.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Painted4coats.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Smoothed.jpg

Still need to give them a light sand and polish, but figured I would slap it all together to get an idea of what it would look like when it's finished:

https://img.photobucket.com/albums/v320/andy36586/GPz750/Panelsfitted109-06.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/Panelsfitted209-06.jpg

I also decided to put some LEDs under the wheel arch to light up when I press the brakes, although I thought they would be brighter, but for less than £3 for 2 strips they are cheap enough to add more:

https://img.photobucket.com/albums/v320/andy36586/GPz750/LEDsfittedoutside.jpg
https://img.photobucket.com/albums/v320/andy36586/GPz750/LEDsfittedinside.jpg

And what they look like when the brake is pressed:
https://www.youtube.com/watch?v=2oNl985WKCU&feature=youtu.be

Now the main thing to work on is the front end, I managed to buy a rear sub frame, so unless I can get someone to fabricate some cheap brackets for the headlights, I might need to chop the other one down to make something, also need to do something about getting the dials moved away from the key slightly.

I just have to finish filling (and do shit loads of sanding) on the petrol tank then get that painted up, throw everything back together and find a bit of private land to take it for a test ride and see what falls apart first.

At the bottom of the 4th picture you can just see my indicators there, I decided to spray them since they were a rather nasty pink colour (as seen lying on the back of the bike here)
https://img.photobucket.com/albums/v320/andy36586/GPz750/loomin2.jpg