Kawasaki Ninja ZX Forum banner

21 - 40 of 57 Posts

·
Registered
Joined
·
785 Posts
Discussion Starter #21
So, I found some grey fiberglass fairings, unfortunately, they have the cutouts for the headlight etc. Now I begin the arduous journey of filling in the headlight holes before I attempt to do another backyard race replica, and continue the search for a race tail.
Id really like to do a 93-95 but finding those is like kinda hard to do.
17571
 

·
Registered
Joined
·
785 Posts
Discussion Starter #24 (Edited)
Seller; bike needs wiring harness.
will not run
no spark
multiple mechanics have worked on the bike
all have failed.
Response; Deliver moto
dont forget keys and title.
 

·
Registered
Joined
·
785 Posts
Discussion Starter #26
So, some people who work on these dinos will know exactly what these last 3 posts are about.
when im sure its right, I will solder and shrink wrap.

Anyone care to guess what Im doing?
17652

17653
 

·
Registered
Joined
·
785 Posts
Discussion Starter #27
JUST GOT SPARK
NOTES;
solenoid faulty
ignition from ebay faulty
battery not providing enough juice
jumped solenoid with new battery, and modified ignition
spark
next.
carb clean and paint
 

·
Registered
Joined
·
785 Posts
Discussion Starter #28 (Edited)
Ok.
it runs.
The 30 year old harness was in bad shape. The harness had been hacked to bits by previous mechanics trying to "hot wire it" The ignition was from Ebay, and those ignitions are notorious to never work.
There was so much corrosion I had to use and old trick to bypass everything in the entire electrical system from the CDI itself.
I had to mod the ignition, clean the contacts at the fuel pump relay (harness side) I had to bypass all safety lockouts at the CDI, I had to straight wire the ignition because the harness plug was burnt and cut to shreds,
I also had to provide at least 12.6 to the system to "unlock" it.
It was a challenge. I have been a zx7r enthusiast for many years and have picked up many valuable tips from members on here and other places.
For that I am grateful. I would never have been able to fire the bike without your help
Thanks alot. Whitehendrix, 57x, Green izbest, ghost zero, toofattoofly, ninjanut, and everyone who puts time in to help out once and a while
pic of the wiring nightmare that now runs thanks to all who dedicated their time to help out the little guy'
And I do the same to pay it forward the best I can
Time to clean the carbs and lets see if it runs good, it sounded healthy when it fired.
All the best, Mace

Edit; The lasr puzzle piece is that the fuel pump doesn't seem to run on its own. I have put 12 volts to it, but it wont click when in 1st gear and starter button pushed.
I can hot wire it, but Id like it to operate properly
these old wiring harnesses are junk man


17697
 

·
Registered
Joined
·
785 Posts
Discussion Starter #29 (Edited)
Checklist;
Ignition modified to provide 6v to grey wire. 1hr
Wiring harness repaired/grounds cleaned/solder and attach new leads 3hr
Solenoid replaced .5hr
Fuel pump tested and replaced 2hr
Cooling system overhaul/ all lines were packed with calcium. 2.5hr
Oil changed 1hr
New spark plugs 1hr

To do;
Headlight diagnosis 1hr
Charging system diagnosis and verification 1hr
Bodywork/ Headlight delete/Sand and Paint 8hr
Brake system overhaul 3hr
Fork seal inspection/Replacement 3hr
Engine degrease and valve cover gasket replacement 2hr
Source Radiator res. cap plug
Clean and polish 2hr
Source exhaust can
Carb clean 2hr

At roughly 37 hours plus parts and being that most shops would just force you replace the harness and ignition, and in accordance with shop labor fees currently at 90 USD an hour,
You can clearly see why bringing an old bike to a shop is not as cost efficient as one may think. With a total of at least 3,000 USD.
( I got used to doing work orders)


Boring pic of some old and new parts (fuel pump was knackered)
17702
 

·
Registered
Joined
·
785 Posts
Discussion Starter #30
!st time on fuel, before carb clean.
it runs better now after a few more test runs, it cleaned out pretty good, ill ride it and see if i even need to clean the carbs at all
hits hard at 5000 rpm.
 

·
Registered
Joined
·
785 Posts
Discussion Starter #31 (Edited)
Spent the day to do a proper clean of the carbs.
Might as well have it running in tip top shape. The idle circuit was all jammed up, cleaned the frame up and degreased the engine, I think im ready to move on to paint and body.
Sounds much cleaner now, didnt want to piss of the neighbors, so i just let it idle to verify the circuit was free.
Needs;
front brakes
paint
headlight diagnosis
oil cooler lines
17741
 

·
Registered
Joined
·
785 Posts
Discussion Starter #32 (Edited)
Low beams work now.
High beam indicator on the pod is not illuminated.
High beams not working yet.
Brakes-DONE/ flush and bleed/lube pistons WORKED.
working on it.
Radiator flushed with prestone flush 3 times. Still not clean.
Dont put tap water in your bike

On deck;

Paint and body
New rear sprocket-ordered

17761
 

·
Registered
Joined
·
785 Posts
Discussion Starter #33 (Edited)
Ok, so the tank was in decent shape, however it had a moderate amount of rust and sediment, and grunge,
After some powerwashing, and some clean up of the petcock, I am getting some good "flow"
(pissing pretty good)
Time to shop vac it for an hour and then add 2 stroke oil to coat.

all vids marked to "private" after build.
its alot of work bro
17768
 

·
Registered
Joined
·
785 Posts
Discussion Starter #34
Got some goodies in the mail.
The old Vance and Hines should sound pretty good after i chop it and do some custom work.
The new sprocket was a must/ the teeth are chewed up on the existing one.
17776

17777
 

·
Registered
Joined
·
785 Posts
Discussion Starter #35 (Edited)
I wouldnt suggest removing the "HEADER SIDE" section of a Vance and Hines, however; The scratches and my desire to keep the badge intact led me here
Its like art or something.
Just need to polish and touch up the logo
17789

TEST FIT
17790

17791

SOUNDCHECK
 

·
Registered
Joined
·
785 Posts
Discussion Starter #36 (Edited)
So as most builders know, life gets in the way.
Havent had much chance to build either bike.
'Searched high and low for a race tail, could not find one.
Had to call Airtech and bite the bullet.
Should make a decent build if the tail ever gets here, Ill let you know how it goes.
Note; cheap chines solenoids from ebay will not work, and will cause bike to continue cranking after you release button.
18067
 

·
Registered
Joined
·
12 Posts
Nice build on that white looks great buddy I've been tinkering with my 97 for a year on and off too with tons of set backs. But It's good to see some people restoring ones in worse shape like that 99. If I remember I'll come back for updates.
 

·
Registered
Joined
·
785 Posts
Discussion Starter #40
Had to say goodbye to project 1 in order to justify putting money into project 2.
New owner taking off pic.
now I can build the other bike although it has a few issues its the most cost effective move.
18781
 
21 - 40 of 57 Posts
Top