88' GPZ600r project -finished *CRASHED* New engine time? :S

[Qwiktune]

Disclaimer: before i start i know NOTHING about the mechanics/electrical workings of a bike. This is a learning project. I am a massive noob


Anyway.......

Got my DAS coming up in a few months and what better way to learn about the bike that you'll be riding than getting a mess and turning it into something awesome.

Anyway, picked up the GPZ from ebay for 100 great british pounds. as modelled by the wife and sprog:


https://img268.imageshack.us/img268/2720/imag0951t.jpg


this is the Ebay description:

''I have cleaned it up mostly, bought a new generator, and tried to fault find the main fuse burn out problem: YES I HAVE HAD IT RUNNING, and it does sound great....it should have a sound motor, but for a 20plus year old bike the loom is ropy as is the rest of the electrics. It have home made flat bars and risers and mini clock. Mini clock hooked upto odo drive.

It is flat black. Brand new rear tye. Chain and sprocket binned due to it being naff. I would add a few inches to the swinging arm geometry but...never got round to it.

The front end was reconditioned, and I removed the bad damping system, machined up spacers and plate for better non standard brakes (Yam 1000s single piston)...''


And thats where i am now. It didnt have a seat/battery when i got it either, although i have just bought a new battery off of Ebay and bidding on a seat.

Next thing to buy would be chain and sprocket i imagine.

This bike also came with a box of spare parts, including original bars etc but most of which i have no idea what they are. There is an air box, i think, although there seems to be a homemade thing going on with some tubing and some cloth:

https://img62.imageshack.us/img62/9186/imag0963.jpg


So my question is, what would YOU do from here? Where do i start?

Do i just stick the new battery in and see what happens?

Main aim, getting it running, then doing cosmetics.


TLDR; Need help


Im gonna attach some pictures and will take some more later.

https://img857.imageshack.us/img857/3985/imag0962.jpg
https://img526.imageshack.us/img526/2263/imag0961.jpg
https://img593.imageshack.us/img593/4546/imag0960k.jpg
https://img853.imageshack.us/img853/4025/imag0959f.jpg
https://img819.imageshack.us/img819/7643/imag0958.jpg
https://img26.imageshack.us/img26/8692/imag0956.jpg
https://img607.imageshack.us/img607/3263/imag0955j.jpg
https://img804.imageshack.us/img804/2047/imag0953a.jpg
https://img838.imageshack.us/img838/3346/imag0952c.jpg
____________________
CBT Passed: 25.05.11, Theory Passed: 12.07.11, MOD1 Passed: 01.04.12, MOD2 Passed: 20.07.12
bikes: Lifan LF125(stolen), Sukida sk125, GPZ 600r, CBR 600F

[Denime]

The air filters look a bit of a botch, I wouldn't trust them.

If you have the air box I'd recommend just getting the air filter, sprocket and chain new from a website like wemoto.co.uk.

Stick the new battery in, try to run it and formulate a list of what's working and what isn't. Maybe change the oil and put in fresh petrol if it's been standing for more than 6 months.

Good luck

Edit: post pictures of the spare parts you recieved with the bike.

[GSTEEL32]

Your loom looks like its been stripped and bodged back. Thats the only part of the bike I'd be wary of. Your fuse will be blowing because of a short somewhere. personally, I'd invest in a second hand loom. They cost peanuts and probably eradicate 80% of electrical gremlins.

The engine will work with those air filters while your finding your way around the mechanics. Get your engine running first.

Invest in some wd40 and penetrating oil before you proceed.

Good luck.

[UnspeedySam]

That's a serious bargain. As has been said. Connect everything up, change the oil, fuel and battery and see what happens.

Don't leave the air filters like that...at the very least get some pod filters.

I've got a feeling that exhaust is going to be stupidly loud...so you might want to replace that if you want an MOT.
____________________
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

[Dr. DaveJPS]

i'd get bidding on a new rear caliper as well!
____________________
"intelligent inattention is preferable to unintelligent tinkering"
www.davejps.com

[UnspeedySam]

[Dr. DaveJPS]

i'd hazard it's probably in the box of parts (i'd hope) i was more highlighting the fact the entire rear braking system is missing
____________________
"intelligent inattention is preferable to unintelligent tinkering"
www.davejps.com

[UnspeedySam]

[Ed Case]

Jeez, that wiring gives a new meaning to 'Rats Nest'. As posted earlier, stick a battery on it and find out what works and what doesn't and take it from there. On the upside you could get more than you paid by 'breaking' it.

[chris-red]

Fuck touching those electrics.


I think you were robbed
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[Qwiktune]

Just got back. Thanks for all the replies guys. New battery should be here tomorrow or thursday so i dont think i'll touch it untill then.

I took some more pictures but its getting dark so they had to be inside and shadows are a bitch.

[UnspeedySam]

That's a big old box of spares! If that engine is relatively sound then that is a hell of a lot of bike for £100!
____________________
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

[evoboy]

I can only imagine what it rides like with that handlebar botch job!

+1 on buying a new loom. Also put the original airbox back on. While your there try to get standard clip-on/bars back on and find a normal exhuast for it.

Other than that, not a bad buy!
____________________
Suzuki GT250 x7------- Fazer 600------CB250RS------Aprilia Rally 70----- Bandit 600

APT Motorcycles

[Qwiktune]

Hmm, so a ''to buy'' list needs to be organised:-


This is the battery i bought: £24.99

https://www.ebay.co.uk/itm/320796319922?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649

Wiring loom? Maybe this?: £18.98

https://www.ebay.co.uk/itm/Kawasaki-GPZ600R-GPX600R-ZX600R-NINJA-Wiring-loom-/150734600785?pt=UK_Motorcycle_Parts&hash=item23187b7a51

Chain and sprockets: £87.98

https://www.ebay.co.uk/itm/ZX-600-GPZ600R-1986-A2-X-Ring-Gold-Chain-Sprocket-Kit-/300574757871?pt=UK_Motorcycle_Parts&hash=item45fba6d3ef

or do i just go cheap/second hand until everything's working and then spend £90 on it. I know it seems silly, but just throwing ideas about.

https://www.ebay.co.uk/itm/Kawasaki-GPZ600-Rear-sprocket-and-carrier-GPZ600R-/370509798226?pt=UK_Motorcycle_Parts&hash=item56441adb52

Something like this?


Seat: £10-£25
Bidding on this at the minute:
https://www.ebay.co.uk/itm/330682798667?ssPageName=STRK:MEBIDX:IT&_trksid=p3984.m1431.l2649

if that backfires theres some on there for around £25

Exhaust

This is something i dont really know about, would need suggestions

Air and oil filters: £17 for both

https://www.ebay.co.uk/itm/Kawasaki-GPZ600-GPZ-600-A1-A5-Air-and-Oil-Filters-/120669975303?pt=UK_Motorcycle_Parts&hash=item1c187db307

New oil, fluid, sprays, cleaners etc: budget maybe £40?




Any suggestions for other things i might need before i get going just post and ill add to my list.

Cheers guys.
____________________
CBT Passed: 25.05.11, Theory Passed: 12.07.11, MOD1 Passed: 01.04.12, MOD2 Passed: 20.07.12
bikes: Lifan LF125(stolen), Sukida sk125, GPZ 600r, CBR 600F

[UnspeedySam]

Don't buy a used chain and sprockets, they will almost certainly be knackered. Try B&C Express, or at least something with a DID chain from eBay.
____________________
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

[chris-red]

Buying a Loom is pretty much pointless, It looks like every electrical component would have had the connectors stripped off to made that bodged loom!

I would leave the C&S to last wait till everything else is working then get it, is it is expensive and not really fundamental at this stage in the build.
____________________
Well, you know what they say. If you want to save the world, you have to push a few old ladies down the stairs.
Skudd:- Perhaps she just thinks you are a window licker and is being nice just in case she becomes another Jill Dando.
WANTED:- Fujinon (Fuji) M42 (Screw on) lenses, let me know if you have anything.

[GSTEEL32]

..... and don't spend £90 on chain and sprockets until your happy everything else is fine too....

It needs to have lights, indicators & a horn. Get those working first otherwise getting it started and through its MOT is a waste of time.

Tyres, chain, sprockets, screens, discs, mirrors, pads and a seat can all wait. To be fair, without hearing the engine working, there's no upside in getting a replacement exhaust yet either.

If you cant get it going, break it, its worth a good couple of hundred in parts. Easy.

Then spend £400 on a working gpz with a MOT. That'll do the trick.

Best of luck.

[UnspeedySam]

[GPZ600R]

Hey up .... I registered extra for this thread. As I have also rebuilt a few GPZs, I thgought I might answer your question of "what would you do".

Firstly you need to ask yourself, do you want to stay streetfighter, or do you want to go back to stock ?
You will probably want to stay streetfighter, as it is probably the "looks" that caught your eye in the first place.

First thing I would do is see if the engine runs correctly before investing any more than needed to determine this.
That Exhaust and those home made sock filter things are going to mess the mixture right up, and she will probably run like a bag of spanners ! (in other words, lumpy as my grandmas custard!)

However, she should still run. Once you know she runs, get rid of those socks and put the standard airfilterbox on with standard filter. Pods look good on a fighter, but can really bitch the Keihin CVK 32 Carbs right up !! (That pipe is doing the carbs no good either!)

Once she is running good, you need to rebuild the bits that are missing.
Yes, the rear brake system is missing, and i dont see it in the box of bits. I only see some front calipers. The PO seemed to have a wild imagination. Whatever made him make those bar holder I really dont know ! Firstly it looks so crap, and you wont be able to ride it for more than 5 miles before your screaming for a nurse !
Thos gaiters on the forks need to be looked at, what are they hiding ? Have the fork seals blown ?

Anyway, get the Brakes fited, a chain and sprocket kit, seat and battery. i would be inclined to fit the oringinal bars, or maybe a proper set of straight bars !

By the way, WD40 IS penetrating oil

Your front forks are totally non standard, the Anti Dive system has been removed. This is not a bad thing, PROVIDING you have progressiv springs fitted. Otherwise she is going to be too soft up front. Might want to watch out for nose diving and see if she is too soft.

I dont trust self made Brake systems either ! I would be inclined to getting the original brakes ultra sonically cleaned and refitted.

You are going to need to study your haynes though, as the brake system is originally connected to the anti dive system.
You will also need to ckech your cooling system. Is it complete, do you still have the coolant resevoir in the bug spoiler.

Yes, its a good project, and for a ton its worth tinkering with.
As said, I would start with the engine, get that running sweet (personally I would have the carbs professionally cleaned too, at the same time make sure the correct jets are fitted!) and then move on to the rebuild.

If you have any specific questions let me know, I am sure I can help you out. Wont be able to come round and help though as I live a bit too far away

Greets from freezing germany
Jason

[Qwiktune]

Thanks again guys, just got up with the kids ''yawn'', but before i went to bed last night i spent an hour or so tinkering in the garage, having a little look around. Ill attach a few more photos.

[GPZ600R]

Mornin, some good pics and info to work on here.

the original bars look so much more safer and tidier. As for the speedo, I would ditch it anyway and try ang det a set of original clocks, that way you wont have any dormant plugs in the loom and all functions will work (Rev counter, warning lights ect..)

Now she is naked I can see the PO kept the original manifold, and just made a rear pipe. This is good as yes, he was able to keep the cooling system intact. The little bottle in the belly pan (bug spoiler) is the coolant reservoir.

The Bike gear changer thing you found on the right hand bar .... is that what you have highlighted in the picture with red ? If you it is a home made choke. At first i thought it was a home made throttle, recheck where that cable goes to, I just cant imagine why he would have moved the choke from the left to right bar, maybe the new speedo was in the way ??

Looking at your pics, I am not seeing the original choke lever .... might want to check this and put a left hand switch unit on the shopping list (but i cant be 100% sure if I just cant see it)

As for the original airbox. If you fit this, then you can ditch that horrible green piece of garden hosepipe acting as a crankcase breather.

Stones and crap in the belly pan .... thats ok ... mine is the same after each year So long as no animals are in there

the whole rear end is not connected to the loom. All those loos wires at the back (green and grey) are for the indicators and back/brake light.

That rusty thing you found is the starter solenoid and looks like this originally ...

https://i79.photobucket.com/albums/j124/Omega25/GPZ600R/DSC04150-1.jpg

Keep the infos coming, sure we can get this running again. I did a couple of rebuilds on the GPZ,, this was my latest, and the current bike I am riding now.

It went from this :

https://i79.photobucket.com/albums/j124/Omega25/DSC03869.jpg

to this: (and believe me, I had every nut and bolt off this bike, and half the engine was repaired too (top half)

https://file1.npage.de/009463/70/bilder/gpz_desktop_small.jpg

[Dr. DaveJPS]

[GPZ600R]

LOL yeah, she was on the center stand when I took the photo, but photoshoped the stand out when I tarted the picture up

well spotted lol

[Qwiktune]

[GPZ600R]

Oh, it was on the left bar ,,, OK that explains it then, the original switch unit on the original bar either didn't fit due to the length required on the straight bar or it was broken, or both
ditch it, take it off the choke (it is fitted similar to a bicycle brake cable)

Don't worry about the solenoid for now. So long as it works, the insides will be OK