[RightSaidFred]

 

[h00ktern]

It hasn't looked so good since it left the factory thirty-three years ago!

 

[RightSaidFred]

Thanks, this is the best part of the process, putting all the shiny stuff back on LOL

the MotoForza replica hugger isnt too bad. Its for a 91-95, but with a bit of trimming it fits OK

 

[RightSaidFred]

Episodes 8 & 9

https://youtu.be/ctsbWgT8w0s

https://youtu.be/1OmwtDcUE_0

 

[RightSaidFred]

Frustrating day today. Made a complete balls of some of the decals.

Ive done decals many many times, but compound curves are my nemesis. Even with some heat and patience, it all ended in tears.

so...I have to order a bunch of new decals for the right side.

1) big white Kawasaki decal for the right lower fairing - went to shit when I got down to the lower rear edge and had to deal with the bend/curve in the panel
2) big blue stripe for the right side /seat panel - 2 sets of compound curves kicked my butt
3) the Japanese letters for the left lower - put it in the wrong place - used the location that it was on my original panel and it seems that was wrong from a previous owner.
4) Upper fairing around the headlights -- no excuse there, I just made a balls of it

The left side I didnt even attempt - A man has to know his limitations.

When the new ones come in Ill ask the local graphics guy to apply the tricky ones, he can wrap a football in a sheet of newspaper with out wrinkles.

 

[RightSaidFred]

Episode 10

https://youtu.be/CNAJfvtnN98

 

[mstng65flcnman]

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:
View attachment 22246 View attachment 22247

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
View attachment 22248

Spares off a different zx7, we will see if these are better than whats on the bike as the restoration moves ahead
View attachment 22249

Spare lower fairings (repaired and painted in an off shade of green)
View attachment 22250

The pin-holes in the fuel tank in the usual location, and some scratches on the frame
View attachment 22251

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 when 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 .

View attachment 22252

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).
View attachment 22253

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:
View attachment 22246 View attachment 22247

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
View attachment 22248

Spares off a different zx7, we will see if these are better than whats on the bike as the restoration moves ahead
View attachment 22249

Spare lower fairings (repaired and painted in an off shade of green)
View attachment 22250

The pin-holes in the fuel tank in the usual location, and some scratches on the frame
View attachment 22251

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 when 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 .

View attachment 22252

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).
View attachment 22253

Hi there is a repro on EBay.fr for about 260 shipped to USA UPS. I got two, they arrived in a strong box with appropriate packing. I tried repairing my OEM original multiple times and was unsuccessful getting a used one with the 1000 dollar plus gouging taking place on ebay.

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:
View attachment 22246 View attachment 22247

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
View attachment 22248

Spares off a different zx7, we will see if these are better than whats on the bike as the restoration moves ahead
View attachment 22249

Spare lower fairings (repaired and painted in an off shade of green)
View attachment 22250

The pin-holes in the fuel tank in the usual location, and some scratches on the frame
View attachment 22251

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 when 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 .

View attachment 22252

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).
View attachment 22253

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.

View attachment 22306

Polycarbonate welding rod
View attachment 22307

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

View attachment 22308

Sanded and back on the bike for now.

View attachment 22309

New repro bottles are available in France on EBay.fr. I got two and they arrived quickly via UPS. They are very strong, i tried to flex them a bit to see the build quality and it seems very good. Now in use on my 1990 to replace my constantly cracking and leaking original Plastifix did not work.

 

[RightSaidFred]

thanks very much for posting, someone posed a link in the other forum a while back, over $350 CAD to get one here, im still mulling it over at that price.

I welded my OEM one, and so far its holding fine but doesnt look the best.

it would be a shame to spoil the look of a freshly restored zx7 with scabby looking coolant bottle, but I need to justify $350+ on it. Ill get there im sure.

 

[h00ktern]

That was me. I just checked the link I provided awhile back, and it shows sold out now. I couldn't find any relistings, so I hope it wasn't a short production run. I was a bit miffed on the price also, but since mstng65flcnman says they're good quality, I might buy one for a spare.

ETA: Found the New Listing
ETA2: Bought one US $282

 

[RightSaidFred]

I still can't bring myself to spend $360 CAD on one

 

[h00ktern]

I totally understand. I paid 303.00 pounds, plus crazy shipping, for an original one. It's the only one I found listed since starting my quest in May '22 - and I checked every day, usually three times a day. So, the $282 US was cheaper on this recreation. If it's good, I'll set my two OEMs on the growing spare parts shelf.

 

[riturbo]

Ya i saw those to but no way can i spend that much . Got a bit excited till i saw the price . My Bike needs other things that are more important .

 

[h00ktern]

I get it brother. I am not rich, and these parts are neither plentiful, easy to find, nor cheap. I have literally searched and bought worldwide, with 75% of the parts coming from European countries (ZXR750.) Ironically, I scored two water pumps from within the US and Poway was able to rebuild both of them for me. Roughly, that is over a grand invested. But what else can one do when a part is unicorn status, and you need it to keep your icon surviving? It totally sucks, but I'm betting the unicorn parts will not devalue over time. I'm scared about crankshaft bearings... - and I don't need them for repair.

 

[riturbo]

I get it brother. I am not rich, and these parts are neither plentiful, easy to find, nor cheap. I have literally searched and bought worldwide, with 75% of the parts coming from European countries (ZXR750.) Ironically, I scored two water pumps from within the US and Poway was able to rebuild both of them for me. Roughly, that is over a grand invested. But what else can one do when a part is unicorn status, and you need it to keep your icon surviving? It totally sucks, but I'm betting the unicorn parts will not devalue over time. I'm scared about crankshaft bearings... - and I don't need them for repair.

Yes it does get pricy . I did drop some good cash on a nos hugger shipped over from europe . Sometimes you have to grab stuff when it’s available.

 

[h00ktern]

Fred, just saw your "I have to sell to make room" video. My pony stable pales in comparison, and you are a stronger man than I, lol.

That sucks. I see double the space above your two rows

 

[ninjanut]

Hooktern. Be glad you do not need crank bearings because they are the fumes that come off the unicorn poop. Ask me how I know?

 

[h00ktern]

That's a great descriptive! I'm almost considering a long shot and buying a spare crankshaft with included main bearings. I wish everyone with an engine wouldn't break it down for parts, or at least do so with some consideration for the buyers. It wouldn't take much effort to run a string of plastigauge before removing a crankshaft or the con rods. I get it, but I think payday overrides conservatism. These bikes are dwindling... Anyway, I'm so far into this bike that I might go ahead with the hail Mary and see what I get. My case was split in '92 or '93 for a new main shaft, and I farmed it out due to work. I almost expect needing to go back in at some point, and I have a complete gear set on the shelf, just in case.

I apologize for going off topic. It's your Thread, Fred