64 replies to this topic

[xr650r2000 TT Bronze Member]

how much did it cost at the end of the rebuild

[Jeekinz Get Help Now]

xr650r2000 said:

how much did it cost at the end of the rebuild

Tools and supplies: Sandblaster/sand $125; zinc plating kit $75; aluminum polishing kit $25-30.  Other materials: various paint $75, various abrasives/sandpaper $20; maybe another $20-30 in cleaners, chemical and rags.

For the bike, I'd say I have at most $1000 in parts.  More than half of that money was in the wheels and tires.  There were a few chrome pieces I had to replace like the shocks and the steering stem bolt.  Those were pretty bad.  I didn't buy the first thing I saw.  For instance, the levers I bout (aftermarket) $15 for the pair on Ebay.  If there was anything that had the "Make Offer" option on Ebay I'd make an offer.  The shocks were listd for $99 + $13 shipping, I made an offer of $87 + $13, an even $100 and they accepted.   Chrome hardware like on the top clamp I sat and polished every bolt.  I did replace some of the small zinc plated 6mm stuff with new hardware from Lowes.  I might have spent $30 tops on new bolts and lockwashers.  I repaired and refinished before I replaced.  The seat had a tear in it that my wife sewed up.  Crap like that will save you a ton of money.

It's still not 'pristine'.  Over the winter I'm going to get all the misc chrome parts together and get them replated.  Things like the rear brake pedal, the grab bar behind the seat.  I'm going to try to repaint the handlebar switches and replace the phillips screws fastening the engine covers.  I probobly have about $150 or so more to spend over the winter.

I can tell you this, having that sandblaster 'on hand' is the only way to go.  I made a friggin beach outside my bay door.  lol  If you think you're going to get away with just getting the frame and swingarm blasted you're wrong.  There's all sorts of small brackets and fasteners you'll need to strip down.  It was definately worth buying.  You should try to buy a pressurized tank system instead of the gravity feed like I bought.  Mine worked 'ok' it just took a little longer.  Just from plating the axle adjusters and a couple other small parts the zinc plater paid for itself, so you might want to look into one of those.

Refinishing the body was the most gratifying. And finding that 2 part clear coat was the icing on the cake and gave a nice deep shine.  The hardest part was waiting for the paint to dry between coats.

[JoseVisage TT Newbie]

Hi Jeekinz,

The restore looks great. I am 90% through my '75 restore that I have been working on for 5 years. Just like you my bike also belong to my dad. I have hit a snag and was hoping you could help me out.

Since it has been so long since I broke down the bike I can't remember how the front of the main wire harness is routed through and around the front part of the frame and the gauge cluster.

Do you have any pictures that show the wiring harness in the front part of the frame? My wires that connect to the front lights are bare and exposed just behind the headlight bucket, are these wires suppose to be tucked inside the headlight bucket? Are these wires suppose to be wrapped in a sleeve? Also, all the electrical works but I have a couple of wire that are not connected to anything, did you have this well or is everything suppose to be connected to something? I am thinking these two loose wires are probably meant to be used on the European models and thus are left unconnected on the US model.

Any insight you have would be greatly appreciated?

Thanks!

[Jeekinz Get Help Now]

Since my bike was basically untouched, I took some pics during disassembly.  The harness with the white tape goes on the left side.  Here's some pics, don't mind those blue connectors, they were for a fairing that I removed.













All the wires connected to something, do you have any photos of yours and the loose wires?  I can take a pic with the headlight removed if you need more help.

[Jeekinz Get Help Now]

BTW, here's she it looks like now.  I decided I want to make it as original as possible, espescially since it's mostly original to begin with.  I got the blinkers on and used the original shock covers w/reflector on the new shocks.  Going to buy some odds and ends for it over the winter, mostly things like replacement hardware, a couple cables, etc. Trying to keep with all Kawi parts too.

[JoseVisage TT Newbie]

Thanks! These really help. I think I may have removed the electrical tape that was covering part of the loom. I will take pictures of what I have going thus far and post. It does look like I'm missing something and will need a little extra help.

[Jeekinz Get Help Now]

No problem.  Can't wait to see some pics!

[tony_d123 TT Newbie]

Great story and I love that budget paint job!

Your old Dad would be very proud.

[CD_Racing TT Bronze Member]

Great job on the restore.  I enjoyed reading this thread very much. Thanks for taking the time to document the process along with all the pics.  I have always loved the sound of the old kawis.  Had a friend in high school whos dad owned a kawi dealership.  He was one lucky kid, always had a sweet new bike, most of the time a 900 or 1000.  All I could do was

[Jeekinz Get Help Now]

Thanks everyone!  

I'm slowly but surely replacing little things.  I just replaced the engine cover bolts and have a few other small items like that on order.  I bought new float bowl screws too.  I'll get an updated pic in a few weeks.

[Greebe TT Bronze Member]

Nice work.  That is cool to have you dads old bike up in tip toe shape again.

[jmoliva00 TT Member]

I had one from late 70's to early 80's. Absoluley loved it! If I could find something similar, as much work as it would be, I'd do it in a heart beat. Enjoy

[martinfan30]

Nice job man!

[aerospot TT Newbie]

I've been think'in bout doing somewhat the same thing to my long stored 74. You've inspired me. http://www.borgporta...otorcycles.html

[DadRider TT Member]

This was an excellent restoration and documentation. Thanks for sharing this with us.

[Jeekinz Get Help Now]

I got around to restoring the handlebar switch housings.  I tried a couple things including using spraypaint in a cup but the thinner used in the paint affected the black base coat.  So I used PJ1 Fast Black along with some $2.50 enamels I bought at A.C. Moore.

Original housings.




About 15-20 minutes later.  I used a small wire brush to help along the stripper.


Then soda blasted any remaining paint.


Make sure you run taps through any open threads after soda blasting.  The soda clogs up threads.


Ready for paint.  PJ1 doesn't recommend a primer using this particular paint.


I like the Fast Black because it looks like a factory finish, not too "wet" like most paints.

[Jeekinz Get Help Now]

Cleaning up the plastic switches.








You have to be real fast using this paint.  It should stand up to bike washes since it's dishwasher safe on glass.  The extra paint wipes off with water, but if it dries you'll have to touch that area up with some Fast Black sprayed in a cup an a small brush.  I had a damp, almost wet paper towel rolled up in a tight roll to wipe off the excess.  Just udab the paint into the letters with a small brush, also brish side to side to really fil up the letters. Then immediately wipe off. I tried a small, damp sponge too but sometimes it picked up more paint than I wanted.  Only do one word at a time.



Back on the bike.

[Kawiboy514 TT Bronze Member]

jeekinz that is awesome i didnt relize you had a z1.. it looks beautiful good job man. im getting a 76 kz 900 friday from upstate texas and i hope to restore it some. well all it needs is a new set of forks and a pipe and its ready to go but i wanna go all out. i cant wait. but awesome job on the bike looks really good.

[Jeekinz Get Help Now]

thanks man!

Those bikes, 76 900's, are pretty desireable too, so I wouldn't ruin anything you can't redo.  There's alot of hackers on these bikes.  I'm on kzriders and Z1 owners club.  Z1OC has more guys looking to preserve the bikes, KZ rider all you see are 1/2 done bobbers and cafe projects.

If your bike is in good shape, or close to it, you'll have a decent investment keeping it as close to original as possible.  Post some pics!

Oh, and the most important thing: Do NOT throw anything away!  Save everything you take off the bike, even hardware, it's all hard to find and worth money.  Complete tool kits can fetch $500+.

[Jeekinz Get Help Now]

I cleaned mine up after sitting in the shop all winter.  I was also able to use my soda blaster on the engine to clean it up even more.  The soda made a complete mess on the bike, I just washed it all off with soap and water.  I wrapped up the intake first tho.

I have a couple small parts I'm getting ready to install along with a larger front sprocket to handle the highway better.