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gpz900 project of bits + Shed and Lift

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pompousporcup...
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PostPosted: 19:14 - 11 Mar 2017    Post subject: gpz900 project of bits + Shed and Lift Reply with quote

Well. I FINALLY found a long term project to take on. I hope it will be worthwhile

It's a gpz900r that is spread over 4 or 5 boxes.

I've been looking for one for a while that didn't cost a left bollock to start with.
Had a poster of one on my wall as a kid!

This thread will be a track and log of its progress. Pics to follow


Last edited by pompousporcupine on 21:48 - 19 Mar 2017; edited 2 times in total
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andym
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PostPosted: 19:54 - 11 Mar 2017    Post subject: Reply with quote

I done a 750 as a project a few years ago, there were a few people that said it wasn't the easiest bike for a first project.... but I didn't run in to too much trouble ( Rolling Eyes ) with mine.

Have fun with it
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pompousporcup...
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PostPosted: 23:08 - 11 Mar 2017    Post subject: Reply with quote

Not my first project tbf and I've dealt with old honda cars as well in my time. Still..It's going to be fun for sure.

It's not as 'complete' as the PO thought it was.. at least some of the fairing is there. I found suzuki parts too Laughing and rusty old calipers that definitely look they're they need to meet the bin.

Haynes manual has been ordered to help as I don't know enough about the 900r


Oh, the best bit so far. Two sets of carbs..both stripped completely. The jets, needles and diaphrams were just in the bottom of a box...loose . Smh
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pompousporcup...
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PostPosted: 08:34 - 12 Mar 2017    Post subject: Reply with quote

its a couple months older than i am Cool genuinely always wanted a bike registered the same year. I can relate to how it looks and feels.. (old Laughing )

It's had a shitty streetfighter attempt done in the past so the rear subframe its going to need cutting off and a replacement bolted on.


An assortment of rusty and broken parts sorted
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3624_zpsvveqea7d.jpg
mmmm
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3615_zpsqvm6dlvv.jpg

How it sits now.
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3614_zpsiiokybzd.jpg
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3613_zpsokjb0dgv.jpg
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chickenstrip
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PostPosted: 13:06 - 12 Mar 2017    Post subject: Reply with quote

pompousporcupine wrote:
its a couple months older than i am Cool genuinely always wanted a bike registered the same year. I can relate to how it looks and feels.. (old Laughing )



Watch it sonny! Laughing

There's another thread about one of these elsewhere here....here ya go:

https://www.bikechatforums.com/viewtopic.php?t=306814

In case you hadn't seen it. Might be of some interest, or even help.
I've always liked these. Will be interesting to see how yours shapes up - looks like you've got your work cut out for you though.
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pompousporcup...
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PostPosted: 16:29 - 12 Mar 2017    Post subject: Reply with quote

chickenstrip wrote:
pompousporcupine wrote:
its a couple months older than i am Cool genuinely always wanted a bike registered the same year. I can relate to how it looks and feels.. (old Laughing )



Watch it sonny! Laughing

There's another thread about one of these elsewhere here....here ya go:

https://www.bikechatforums.com/viewtopic.php?t=306814

In case you hadn't seen it. Might be of some interest, or even help.
I've always liked these. Will be interesting to see how yours shapes up - looks like you've got your work cut out for you though.


Ah, great pics in that thread Thumbs Up

Ive been having a think and in all honesty, i cannot be bothered with an all original/period restore. As long as its recognisable as a gpz9 and rides/stops well then i'l be happy Smile

The wheels and front forks are from a later spec 900r (the front being 17 inch rather than 16) and they accomodate wider tyres that are easier to find. Similar to the gpz500 wheel size revisions.
As these are fitted, i'l leave them on a tidy them up.

WILL need new calipers as after taking into account new pistons it works out around the same price -_-
WILL need a new rear subframe and the frame needs a lick of rust proofing.
The loom has been hacked at some point so it may just be easier to buy a complete one off ebay.

The required parts list is getting fairly big
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tony_d123
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PostPosted: 16:36 - 12 Mar 2017    Post subject: Reply with quote

Wow, you have your work cut out there. If the brackets haven't been butchered, the standard rear sub frame just bolts on. Will be watching this with interest Very Happy
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pompousporcup...
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PostPosted: 16:38 - 12 Mar 2017    Post subject: Reply with quote

tony_d123 wrote:
Wow, you have your work cut out there. If the brackets haven't been butchered, the standard rear sub frame just bolts on. Will be watching this with interest Very Happy


Luckily, they havent Cool The PO just welded a tube to one of the existing rails. The hangers (bit the foot rests/brakes are mounted to) line up perfectly but cant be put on until the subframe arrives Thumbs Up

Yes. I do. The inside of the tank looks like the underside of an old ship.

*Off to work out how to clean and re-line it
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tony_d123
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PostPosted: 22:18 - 12 Mar 2017    Post subject: Reply with quote

Wow, you have your work cut out there. If the brackets haven't been butchered, the standard rear sub frame just bolts on. Will be watching this with interest Very Happy
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pompousporcup...
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PostPosted: 16:36 - 15 Mar 2017    Post subject: Reply with quote

Spent the last few days working out what parts i need and what random assortment of parts this bike has on it

it has zr750 zephyr forks and wheels and yokes. Makes it nice and easy to fit regular bars rather than the risers it originally came with.

I've managed to get all but 2 of the rusty exhaust studs out without much issue. The last 2 i am plus gassing for the next week before trying again. Also bought an old exhaust manifold which needs some repairing for cheaps

Doubt il get much done on it this weekend as i have a shed base to build and a bit of a project with one of these to start
https://www.ebay.co.uk/itm/380922360214?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
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pompousporcup...
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PostPosted: 22:11 - 19 Mar 2017    Post subject: Reply with quote

update:

Havent done much on the GPZ project other than attempting to remove the bodge streetfighter rear subframe and fitting a zr750 zephyr bar mount to go with the top yoke. Life, house renovation and other projects took enough of my time this weekend.

Still. I got a fair way building the new shed/workshop/garage overflow.

New fence with concrete posts to replace the old and rotten one left by the PO of the house. Quite expensive really considering its..a fence. Looks decent though and surprisingly its straight. Although the father in-law had more to do with that than i did.

Fence up. Laying the slabs to keep the shed off the ground. The ground slopes away quite a bit making this a proper ballache to get the levels set.
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3647_zps8gdelu15.jpg

Base of shed built. I have a new found interest for working with timber. I've not really done anything this involved using timber and concrete
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3651_zpslumkj3i7.jpg

AND the floor on
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3653_zpsclcbeakw.jpg

For those interested(i know, its a shed) it measures 14ft x 6ft. Space is fairly limited and i still wanted a path through to the garden wide enough to wheel a bike/wheelbarrow through.

Next project starts with one of these Smile
https://i176.photobucket.com/albums/w188/Sharpe2002/IMG-20170319-WA0001_zps8w5gms5a.jpg

I've already cut it in half. Brand new, never used. Must be mad Laughing Plan is to extend the two halves by 7ft and build a slightly raised platform to make a DIY bike lift.


To top off a decent weekend, i watched as the wind blew my bike over. Too far away to reach it in time all i could do was a kind of slowmo 'Noooooooooooo!'
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pompousporcup...
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PostPosted: 20:07 - 23 Mar 2017    Post subject: Reply with quote

bought another one. Laughing
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tony_d123
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PostPosted: 21:17 - 23 Mar 2017    Post subject: Reply with quote

It's an illness, once you start collecting them you can't stop Smile
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pompousporcup...
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PostPosted: 22:26 - 23 Mar 2017    Post subject: Reply with quote

tony_d123 wrote:
It's an illness, once you start collecting them you can't stop Smile


truth. I'l need to be selling the little gpz500 now to make space as the workshop is getting a tad crowded Laughing

https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3658_zpsbitnvx8z.jpg

https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3660_zpsikcffazn.jpg


It was a long almost 7 hour round trip to pick it up but at first glance looks to be worth it. It came with plenty of spares that can be used on the early model project which is going in for media blasting next week Smile Its also very nice to have something to reference against when working up from nothing but a frame and wheels

Renthal flat bars have been acquired for the early model due to a mistake made by my mate ordering bars that didnt fit properly. Laughing I 900 tank sits a bit differently so i dont think i'l have the same issues he did
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Chris45
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PostPosted: 19:11 - 31 Mar 2017    Post subject: Reply with quote

Quote:
Still. I got a fair way building the new shed/workshop/garage overflow.


Just hope the new shed is purely for the bike build and not as another family store room! I have a full sized garage and until recently couldn't get into the fekking place. Kids old toys and household junk etc, etc. Hired a full sized skip one weekend and chucked the lot out. Fortunately we live in a cul-de-sac so it was easy to arrange and do.

The new shed is taking shape there chap, and all I can say is best of luck with the bike build. No doubt there'll be plenty of advice on the forum if you can't figure out some of the trickier aspects. After refurbing my 500s, am currently looking at building a complete bike from parts. Heading off to Falkirk to see a frame and assorted bits this weekend Thumbs Up

Keep us posted on how the shed and bike build progress.

Chris
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pompousporcup...
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PostPosted: 10:44 - 01 Apr 2017    Post subject: Reply with quote

Cheers Chris. My 500 will be for sale shortly with tons of spares. I stripped that one down to a frame and replaced every bearing/bush before putting it back together. It was good fun Thumbs Up They're very simple bikes to get your head around.

The 900. Same on principle, everything is just heavier and older Laughing

What bike are you looking to build up from a frame?
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Chris45
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PostPosted: 16:57 - 01 Apr 2017    Post subject: Reply with quote

Am going to see this tomorrow -

https://www.gumtree.com/p/kawasaki-motorbikes/kawasaki-ex500-d7-rolling-frame-with-broken-engine-spares-or-repairs-project./1222238702

If I get it, hope to have a rebuild started over the summer. Everything off the frame of course, and I'll do a respray with semi professional equipment. Then source parts. Not too worried about the engine, it's a scrapper, and there seem to be plenty on fleabay.

Deffo want to rebuild a bike from the ground up. Working in the garage every night - big mug of tea and the radio on Very Happy
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pompousporcup...
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PostPosted: 15:54 - 18 Apr 2017    Post subject: Reply with quote

finished the shed. i got a chest infection which has completed floored me for the last 2 weeks or so and working up the energy to do stuff to the bikes and finish this has been a bit of a battle.

Of the shit pics i took.
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3734_zpsanbq9mwr.jpg
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3739_zpsjtlnat0v.jpg


Bike wise, i've changed the plugs, completed an oil change which saw the best part of 7l come out (sump takes 4l accordingly to the manual so there was 3+ litres of petrol in there rendering the oil next to useless.

carbs have been stripped, cleaned and rebuild but carb #3 is leaking slightly so i need to see what the problem is there.
The Givi rack has been removed.

The rear sprocket carrier bearing needs replacing as well so i'm going to get a front and rear bearing kit for peace of mind.

More updates to come
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pompousporcup...
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PostPosted: 10:15 - 24 Apr 2017    Post subject: Reply with quote

IT LIVES!

After trickle charging the dead battery for a few hours, checking all fluids and using a temp fuel supply. The bike started right up. Needs a bit of tune up and may still put the stock airbox back for ease sake once its all done. Wheel bearings are on the way so that's the next job on the list.

Fan kicks in as it should which is a relief.

https://youtu.be/fH5c5FWjPKo
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CliveFa
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PostPosted: 10:45 - 24 Apr 2017    Post subject: Reply with quote

I had a GPZ900R in the 80's - an excellent bike.

Note that the eccentric rear axle mount that adjusts chain tension - also alters ride height and therefore handling. Took me a little while to figure that out.
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pompousporcup...
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PostPosted: 11:05 - 24 Apr 2017    Post subject: Reply with quote

CliveFa wrote:
I had a GPZ900R in the 80's - an excellent bike.

Note that the eccentric rear axle mount that adjusts chain tension - also alters ride height and therefore handling. Took me a little while to figure that out.


i suspected it would do that. seems a daft idea really as the axle could by over an inch higher depending on how long/warn the chain is Confused
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NutsyUk
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PostPosted: 11:55 - 24 Apr 2017    Post subject: Reply with quote

You must like Jigsaws Very Happy

Good luck Very Happy
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pompousporcup...
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PostPosted: 19:51 - 24 Apr 2017    Post subject: Reply with quote

i do Laughing 25 pieces max though
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pompousporcup...
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PostPosted: 12:08 - 05 Jun 2017    Post subject: Reply with quote

little bit of an update:

I replaced the chain and sprockets on the later gpz900 and also put a new speedo cable on. getting closer to being MOTd Cool

https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3783_zpselr6erlz.jpg
screwdriver makes it look better than it was. I could pull it off the sprocket with a bit of effort. I think the old owner used kids play sand mixed with tyre Goop as lubricate. It 1cm thick in places.

https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3804_zpswxosfxtz.jpg

The front sprocket was a giggle to get off. Looped the old chain round the rear axle with a screwdriver through it. Put an axle stand in front of the sprocket with a 1/2inch bar across it and then a 3ft pole on the end of the ratchet... it took my weight for 5-6seconds and then let go with a proper crack noise

Rear caliper has been rebuilt with new seals, fluid and new pads. Snapped a bloody bleed nipple in the process though which was not fun.
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pompousporcup...
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PostPosted: 14:32 - 20 Jun 2017    Post subject: Reply with quote

taken from the WHYDTYBT thread for continuity sake

took advantage of this fantastic weather to replace the 15 year old tyres with fresh rubber and give the ol girl a good wash n wax

new motobatt fitted along with avon roadriders (stupid 18inch rear wheel limiting choice).
I also fitted a jet kit to help it run better after using pod filters.

It cleaned up really well and after using MER i could see my reflection in the panels.

https://i176.photobucket.com/albums/w188/Sharpe2002/19222902_10155295644057464_9171451810755254770_o_zpsp4bkkmhq.jpg
https://i176.photobucket.com/albums/w188/Sharpe2002/19264380_10155295644052464_3891569955577664645_o_zpseglwoo5p.jpg

MOT is a week today.


I also painted a red tank black. Not perfect but passed the 5ft test. I'l add Kawasaki sticker.
Unfortunately a lot of the original decals are no longer available, even direct from kawasaki

After 3 coats of primer, satin black and clear.
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3835_zpsfzq0gn2p.jpg
https://i176.photobucket.com/albums/w188/Sharpe2002/IMAG3838_zpsb0ovhql7.jpg
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