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'90 ZX7, Africa Twin, M109R, VFR800, RC8R, RSV Factory, Rossi R1,NS400R, Z1000, ZRX1100, 1125R, xb9
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Discussion Starter · #1 · (Edited)
Hi Guys, the build wont get under way for a while yet, but I thought I can at least start a thread on it with my initial thoughts and discoveries (we all love pictures etc right ?). Ill post pics of the bike, parts I have , any new bits I get for the project etc.

So Here we go...

Its a 1990 H2 ZX7 - With help form "ninjanut" I have confirmed its a legit H2. It has the "3.3l" stamped clutch cover, curved Rad, build date 02/90, H2 Frame, H2 VIN number Range. Its got 66,000km on it.

Main items I see that are obviously missing:

-Hugger Fender
-Left Mirror (Green) I have the right one and the bike has black repo ones on it now
-Rear Fender & Signal Lights
-Infill Panels that fit between the fairings and the frame (though I do have the brackets for them)

What I see thats broken or needs fixing /replacing/attention

  • Battery Box - butchered, If I cant find a new one (unique to 1990 Im told) ill have to rear this one with the help of some pictures form someone here with a 1990
  • Rear Fender is in a parts box but its hacked up pretty badly
  • Coolant reservoir bottle is cracked badly
  • Seats are "ok". I have 2 sets of seats, so may get 1 good rider and one good pillion out of the 2 sets - if not ill re cover them
  • Bodywork - typical for the age and use - its generally pretty good but the lowers need work. It will get a full repaint and new decals
  • Fuel tank - looking inside its very clean. BUT.... it has the typical pin holes coming into view at the Botton left of the tank seam (you know, where the condensation pools as water when left on a side stand for years). Now, I HATE HATE HATE, tank liners, so the plan here is to clean that inside section of the tank and rid it of rust, and then ill solder the tank pin holes.
  • Frame - im happy its not been polished, however it does need painting, there are several scuffs and scratches that dictate the need. I'll likely repaint it as opposed to powder coat, the PC company up where I am is awful, I had 3 VF1000R frames done a few years ago and sent them back to be stripped they were so poorly done.
  • Wheels - decent shape but need paint and new tires and ill put bearings in at the same time.
  • Brakes - usual calliper dismantle and clean, pads, MC clean and service
  • Clutch Slave is leaking - needs a seal
  • Head Bearings - will replace just because
  • Engine - runs good for a bike thats been sitting for 7 years - no smoke, a bit lumpy on idle, but rev's out nicely, and drives ok. Ill do a compression test, valve clearances etc. a general clean and paint as needed, flush the cooling system, change oil etc
  • Carbs will be torn down and cleaned in the ultrasonic cleaner - I will likely buy a carb kit from "LiteTeck" in Thailand, I've head great success with their gasket & seal kits in the past
  • Exhaust - as much as id like OEM, it doubt ill find one, it currently has a full Muzzy system on it, the headers and mid pipe are rusty but not rotten, the can needs polishing and some new rivets. Headers and mid will get media blasted and painted and likely a titanium heat wrap on the mid pipe.
  • Forks - some refinishing needed on the lower legs, will rebuild with new bushings and seals
  • All the lights and signals work, but I'll go through the electrical and check charging etc
  • Fasteners - ill have to source decent stainless or OEM fasteners, many of these are rusty and just plan wrong
  • Windshield - may or may not leave the one thats on it...undecided, I usually prefer a clear OEM type look.

Whats been Ordered so far

-Rear Signals lights off EBAY
-Shop Manual off EBAY
-Decal Kit - fromAFE Graphics (RDDecals.com)
-Solo Cowl from AirTech
-Reflector for the right lower fairing and rear Lic Plate reflector from CMSNL

What Im looking for (if you have any of these things please let me know) :

-Left and Right Infill Panels
-Rear fender (where the signals mount)
-Coolant Bottle
-Battery Box
-Left green mirror

The Process I follow :

1) Create Initial Inventory of whats missing or what I need to buy or fix
2) Acquire the items from step 1, I dont start the build until I have what I believe is everything I need (but there are always surprises)
3) The tear down - I take 100's of Photos as I dismantle the bike, I keep a note book and every step is recorded, every part, nut bolt etc is bagged, labeled and numbered according to the steps in the note book. Any extra parts or problem areas are noted and source those parts as well.
4) The repair - I do my own bodywork and paint, I do my own engine work and mechanical, and I do "some" of my own upholstery if no stitching is required. I out-source the tire mounting and difficult upholstery work along with rebuilding of starters etc. If there are know paint matches, id like to hear about them form members here, otherwise ill take the best panels to my paint supplier and have them optically scanned for a match.
5) The build up - pretty much the reverse of the tear down
6) The testing - in shop startup and initial heat cycle, followed by a road test

I also keep a expense spreadsheet so I can keep detail track of what I have invested into each bike.

I do take videos too, but as of now we have awful internet where I live (Up North, in the middle of no where, rural, with only cellular internet, at astronomical Canadian rates, and very slow) so until Elon sends me my StarLink dish, the vid's wont be on Youtube for a while.

Here are the initial pictures of the bike and parts:
Tire Wheel Fuel tank Automotive fuel system Vehicle
Tire Wheel Fuel tank Automotive fuel system Automotive lighting


Not sure yet what the 3 small metal bits are here, the 2 (L&R) pieces are likely striker/guide plates for a seat latch maybe?, and no idea whet the triangular bracket is off , maybe you guys know (may not be off my bike as there are extras in the box that I know came off different ZX7, ill have to scan the parts fiche to find out). Other than that we have a spare seat, the hacked up rear fender, the infill panel brackets, the "chain cover", and the OEM Right side Mirror
Font Tints and shades Wood Metal Carmine


Spares off a different zx7, we will see if these are better than whats on the bike as the restoration moves ahead
Automotive parking light Automotive tail & brake light Motor vehicle Automotive tire Automotive lighting


Spare lower fairings (repaired and painted in an off shade of green)
Green Motor vehicle Tire Bumper Fender


The pin-holes in the fuel tank in the usual location, and some scratches on the frame
Hood Leaf Terrestrial plant Automotive exterior Bumper


The biggest atrocity on the bike, Missing hugger, missing fender, flush mounted signal lights, and a stainless fender /lic plate mount substitute. I get queasy what I see this kind of thing. its my biggest pet peeve, although I know it was a popular modification " back in the day" EDIT: I guess its still a popular mod today to use a tail tidy, im ok with that but dont like to see the OEM stuff hacked and chopped .

Tire Wheel Vehicle Fuel tank Automotive tire


The coolant bottle, likely smashed when the bike went down on the right side. I'd like to find a decent reservoir bottle to replace this one, or find a decent looking substitute (ideas welcome).
Hood Motor vehicle Eyewear Sunglasses Vehicle door
 

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'90 ZX7, Africa Twin, M109R, VFR800, RC8R, RSV Factory, Rossi R1,NS400R, Z1000, ZRX1100, 1125R, xb9
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Discussion Starter · #2 · (Edited)
Here are a few bikes I restored in the past, all of these were frame up resto's

87 RG250 WalterWolf
Wheel Tire Sky Vehicle Fuel tank


88 RGV250 VJ21 - J JDM only bike, very rare
Tire Wheel Fuel tank Automotive lighting Automotive tire


VF1000R

Wheel Tire Fuel tank Land vehicle Automotive fuel system


VF1000R in Euro Colours

Tire Fuel tank Wheel Vehicle Automotive tire


a Fun /Non OEM build - Kevin Schwantz tribute 1993 GSXR750
Wheel Tire Automotive lighting Automotive tire Vehicle
 
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Nice post . Good luck finding a rear fender or a coolant bottle . Ive been looking for years . Did manage to find the hugger new last year but was in england . Cost a fortune but did get one. Will be following along .
 

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Discussion Starter · #4 · (Edited)
Thanks, yea I know some of this stuff is either like rocking horse poop or made of unobtanium.

I took a flyer on a fibreglass hugger from the chec republic, since its FG it should be simple to modify if need be (it fits a 91). I may take a shot at repairing the rear fender I have with a donor fender off another bike if I can identify one 9" wide.

And I’ll weld the coolant bottle if I can’t find a replacement , either that I’ll find a substitute from somewhere. I have one off a CB1 that’s close to the right shape, but i think it’s going to be a bit too wide. saw one on Ali express and one on Amazon that could work (but look different and my need to be located elsewhere.

I’m sure some of this stuff could be 3D printed by someone with the right skills and printer .
 

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Discussion Starter · #5 · (Edited)
Rear turn signals on the way from Ebay

Hugger on the way form Chec Republic - MotoForza ( ill modify to adapt a fit)

Brake pads ordered

Carb kit ordered from Litetek in Thailand

Ordering the bearings and seals today (From Kawasaki)

Airtech Solo Cowl ordered

Decal Kit ordered (AFE Graphics /RDDecals.com)

Reflectors should arrive Thursday from CMSNL (right side fairing and rear one for the fender)

2 possible donor fenders on the way from EBAY, hopefully one of them will fit the bill, they are 9" wide and will be surgically cut and grafted on to the chopped base of my OEM fender. Ill be plastic welding the fender and using Plastex plastic repair as well... More to come on that.

Im also going to try and plastic weld my coolant bottle. All the bits are there so we will see how the old UV battered plastic behaves under welding conditions. Ill coat the welded seams in "polyall2000" to smooth them out a bit more and then paint it white. Ill continue my search for a replacement, but its worth a try in the mean time. Polyall2000 is a 2 part liquid, polyurethane plastic. 50/50 mix, viscosity of water when first mixed then hardens in minutes and sands in minutes. Im not sure its even still available any more but I still have some here and it works VERY WELL. Ill post pics of it when I get to that point.

A Few other missing items are also in the works as well.

Tires and paint will wait until I'm closer to needing them

here is the Motoforza hugger....
Automotive design Font Logo Circle Darkness
Automotive design Font Event Thumb Fashion accessory
Tire Wheel Automotive tire Vehicle Hood
 
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Discussion Starter · #6 · (Edited)
Weldedup the coolant reservoir this morning. Its not pretty but its in one piece and doesnt leak, so it will do until something better comes along.

Seems these are made of PolyCarbonate plastic. Nothing sticks to that stuff (not epoxy, not plastic paint, nothing). Welding is pretty much the only option.

Couldn't use the Polyall2000 as it wont stick either

Had some PC welding rod so used that to weld the cracks and fill some holes (several pieces of the bottle crumbled away leaving holes ) and then sanded the whole top part down smooth as I could.

I'd planned to paint it white with Krylon Fusion, but nothing sticks to this type of plastics I had to abandon that.

White Glove Clay Finger Safety glove


Polycarbonate welding rod
Hand Hood Gesture Sleeve Finger


80% of the welding done, still a few visible cracks here that I still had to do.

Hand Arm Leg Human body Jaw


Sanded and back on the bike for now.

Tire Hood Motor vehicle Automotive lighting Automotive tire
 

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Discussion Starter · #7 ·
This bike will be coming totally apart, but until then (winter), ill putter around with a few things, and try and keep this thread current. I have a 84 CBX750 to restore before I get to the ZX7.

Not sure if you guys know about this product but it does a great job to restoring your faded black plastics like signal lights and handle bar switch gear. Ive taken stuff that was almost white it was faded so badly and taken it back to black with this stuff.

Its "Kleen flo honey goo Holisitic Rubber Care". you spray it on and leave it, if it soaks in spray it again the next day etc until it doesnt soak in any more.

Forgot to take a before pic, but my signal lights were faded to grey. They will get a few more coats yet. Then we'll decide if they good enough or need to be replaced (if too scratched like this left front).

Ive also treated the cap on the coolant reservoir today with it, it was also fading.

Hand Finger Nail Tints and shades Wrist
 

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Discussion Starter · #8 · (Edited)
Decals arrived today, it will be a while before they get applied.

AFE Graphics/RDDecals.com/CBDecals.com. (Same company) produce some of the best quality decals I have ever used. If they have what I want, I usually buy there. These Kawasaki decals came from there.

If they dont have what I want, I buy from the Image Works in the UK, equally fantastic product.

Received notice that my hugger has shipped out from Chec Republic too.

My Factory Shop Manual arrived off Ebay too, its like Christmas !!

Motor vehicle Hood Automotive tire Automotive design Automotive exterior
 

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Discussion Starter · #9 · (Edited)
This is what's on the lift just now, a 84 CBX750F. You may not have seen one of these if you're in Canada or the USA (they were never imported here). This is a JDM spec bike imported to Canada who knows when. Same inline 4 as the 750 Nighthawk S.

Once this one is done the ZX7 will have its turn. I have been tempted to move the ZX7 ahead of this one, but since I've already started this ill keep at it. It will give me something too look forward to, a ZX7 has been on my list of restorations for a long time.

Tire Wheel Fuel tank Automotive fuel system Motor vehicle
Tire Wheel Automotive fuel system Fuel tank Motor vehicle
 

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Discussion Starter · #10 ·
The gentleman I got the ZX7 form just contacted me that he has some additional tail panels for me.

Great to have spares ! Will pick em up next week.

Very nice of him to reach back out, there are some really great people in this hobby !!!! including guys on this forum who have been VERY helpful.

Hand tool Tool Backsaw Pipe wrench Font
 

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<new member>
If you didn't get a reply yet and haven't figured it out, the three little metal bits are as follows:

1) the two triangular winglet looking things mount on the sides of the rear subframe, at the rear. They're like little filler panels.
2) the remaining metal piece looks like a rear tail panel mount, where the front tab joins near the tank.

Going through the same process on mine, original owner, twenty-eight years of garage storage after eating an SUV in '94.
Tire Wheel Bicycle Bicycle frame Bicycle tire
May Tire Wheel Vehicle Automotive fuel system Fuel tank
Now.
 

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Discussion Starter · #12 ·
That’s great, thanks for the reply !!!!!

Yours is looking great !!
 

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Thanks, but it looks better in the photgraphs than it really is. I still have paint and bodywork to do...

If you don't mind elaborating, can you advise more on the reservoir repair? My tank survived in pretty good to excellent condition, albeit with a tiny crack at the rear mounting tab (screw.) It is above the High level mark, and shouldn't be a service problem, but if over-filled, it develops a bead of water, which drops away before another bead begins.

I just bought a Polyvance N2 hot air welder (w/ a secondary airless,) and an assortment of plastic welding rods. I plan on fixing a few ABS cracks, misc repairs to an eBay upper, and nip the coolant tank in the bud - before it gets worse.

This is a new venture for me, and I understand it all fairly well (I MIG a bit,) except, none of our plastics appear to have the identifiers molded in. So, if you have any advice, I'd be glad to read it.

I'm guessing others might find it interesting also, since OEM plastic is slim pickings, and I suspect plastic welding is the only way forward.

Anyway, I don't mean to hijack your thread if you don't really want to get into it. Your work seems very good, and fixing up another H2 is a great endeavor. I look forward to your progress.
 

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Discussion Starter · #14 ·
I just use a soldering iron and Polycarboante welding rod. You can buy multi packs of various types of plastic wedlock g rod on Amazon .

You basically melt the cracked plastic on the reservoir and the welding rod at the stem time , like welding metal really.

You may actually find it a bit easier to just use the soldering iron on the reservoir first and melt the crack back together first. Then Go back and use the polycarbonate rod to fill in the voids .

Don’t stay too long in one place with the soldering iron or you’ll have more damage than you started with

Once done you can sand it off , I used my Dremel tool but be careful it eats thru the plastic tank in a hurry

It would be a good idea to practice on an Old bit of abs fairing first . Hone your technique, That reservoir will melt a whole lot faster that the abs fairing so it’s easy to make a mess of it
 
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