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Discussion Starter #1
Just thought id start a thread as I am near the start but hammering through a project on a total wreck of a bike.
I bought it not knowing so many parts were missing.

Ill add to this thread constantly but ask questions away from it.

This most certainly is a winter project not the couple of weeks turnaround i wanted.

The high level is: to get it looking "ok" but mechanically perfect
with full nut and bolt mechanical restore....... and ride the thing this summer.
 

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Discussion Starter #2
Issues: and progress

Doing multiple things at once as have time off.
the barrels are off being blasted so I am leaving the engine for now.
This is going to be hard as there are bits missing and i am going to need a new head.

Spraying the smaller bits at the moment and ill do all wheel bearings and steering head bearings next week.
I am not going to shot blast the frame -- yet but probably should.
 

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Discussion Starter #3 (Edited)
Carbs renovation:

these were filthy. All pulled apart , many bolt heads stripped off and had to be removed.
Now replaced with allen key bolts.

All carbs now cleaned but one float post broke - now fixed with jb weld.
Also i ruined a pilot yet head removing it.

All good to go now but not resprayed - mechanically sound only.
 

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Discussion Starter #4
I thought i had started rebuilding but no - plenty more issues !

This bike has been through the wars for sure.
The state of the overall mechanics ......

But looking in the sump it was clean ! as the previous owner did say it had not blown up !
 

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If the gpz has cup and cone with loose ball bearings at the steering head, a tapered roller bearing kit there is an upgrade (and probably cheaper than the oe parts) --- as for the carb float pivot repair = I've seen a few posts claiming jb weld sometimes doesn't stand up well to ethanol blended gas? Once the barrels are blasted, make sure they are super clean= grit can f--k an engine!!! All these points you may have already considered but they're worth repeating.
 

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Discussion Starter #8
All points taken on board but I will go with it and run it with jb weld and report.
The carbs are fine bar this one float post now fixed it seems with the jb weld.
If it works we will all get somewhere.
If it does not then its out with the carbs again - but with this bike this is going to be the way for a while
after first starup.
Until the engine goes with my reconditioning I dont want to spend too much on it.

As the bike is in such a state I am eager to see the engine going asap.
Due to it missing one cam cap I need a new head ! hence my despair.

I had a look at the rear wheel and swigning arm and will clean those up.
I have decided not to replace the bearings at this stage and will do as and when.
I wanted really to see what bolts are stripped as I have had many many so far and I am now down to the last one
on the frame.

the only way I have been able to get these bolts out is to drill out with HSS/ Cobalt and carbide drills.
LH or RH drills made no difference and have always had to re tap the threads.

You will never have seen such a poorly mainteained and kept bike.
I think it had been outdoors since 1996 !
 

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Discussion Starter #9
im watching those junk carbs you told on ebay.
Good idea ! I will report on how the jb weld fix goes though and place here.
 

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Discussion Starter #11
Spraying panels and metal parts and cleaning up the electics.

I have I think now sorted all stripped bolts head , threads on the bike.
I have realised that you need to know about HSS , Cobolt and Carbide drills to drill
out stuck bolts oneself !
I ven bought the LH drills to get the bolts out to no avail.
I also used various LH thread tools to pull them out to no avail.

I have had to re thread them after drilling them out just smaller than thread dia.
All sorted myself now anyway and money saved.
 

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Discussion Starter #12
a few massive days on the bike ... the most awful doing the forks for new fork seals.
(I have one to do)
A nightmare due to not having an air impact drill to remove the lower allen bolt.
Will post later details on this but am investing in an electric impact drill to do em up and
remove other bolts in the future.

But work continues a pace as i want this going by spring.
Spraying up parts, checking engine for missing parts, ordering second hand cylinder head, spraying brake callipers
and sorting and sourcing brake parts.

Electrics which is gonna hot me soon still going to trouble me but
I have all the connectors cleaned up.

With luck this bike could go in one month ! with luck ! and electrical help ..... and help
on adjusting valve clearances !! ill ask that in a post ! it seems the shims are inside the boots ?
That makes adjusting an absolute nightmare ?????????????
 

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Discussion Starter #14
I will need some luck with this one ! It was way past saving --- for me really but it will be saved.
It was meant to be a 2 week quick project for a run around !
It is now a battle of wills to resurrect this wonderful bike.

So many parts missing and so much to do - it is almost bewildering.

Cylinder head:
the second cylinder head is in good condition but one exhaust stud has cracked the casing slightly.
All the studs have been re tapped to M8's not the standard M6's.
I am now having it checked to see if it needs skimming.
the issue will need welding ...or some job weld.
(ill post a picture later and ask for advice)

cylinders:
I think all the cam chain guides are missing.
As this bike was in bits it is so hard to do everything from diagrams and order or find on ebay.

Forks:
the more I look at the diagrams the more parts i see are / were missing.
I think i have them all ordered now o get the bike on its wheels again to make room
in the garage.

Anyway it does progress - all brake calipers are now like new, side panels and other panels in primer.
All metal bits other than swinging arm and frame all sprayed up - no rust anymore.

Still need:
-the internals for the rear master cylinder (or unit complete)
- the right side stand (there is something wrong with the current one - will look into)
it is as if the items on the parts diagrams are not actually correct ?

I think if the tank is in primer by Friday I will be half way and a massive
jump forward.
 

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If not already done so, you should drop the oil pan & make sure there's nothing in there that shouldn't be & make sure the oil pump filter is free of any debris, you might even find some chewed up camchain guides in there
Pete
 

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Discussion Starter #16
when i bought the bike the sump cover (oil pan) was loosened.
inspection showed it was clean with a few bits on the strainer / filter.

This could have been cleaned before i got there?
the barrels and cylinder head were off when i bought it. It was a wreck but informed engine ok !
cylinder head missing bits ! (i now have a second head but with 1 broken exhaust bolt hole )
this i am thinking how to fix - even with jb weld or loctite. will show pics soon.

one issue (now fixed) was a totally stripped oil drain bolt thread and poor quality bolt still in situ.
This now helicoiled and proper bolt and washer sorted,
i think this was the reason the cover was off.
the mechanics / engineering on the bike were appallingy bad ! I must have gone mad to buy it
but it is my responsibility now to get the bike mechanically sound ... and going.

i am yet to put the sump back on - cleaning old gasket with razor blade at mo
and my dremel and brass brush method.....
 

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Discussion Starter #18
Barrel and cylinder head went off to engineering firm to be checked for warpage ....

Barrel:
Pots ok but needs skimming
Cylinder head:
Needs skimming (but has 1 broken out exhaust bolt to fix - will show pics soon
and must decide to use jb weld/loctite/aluminium welding ...)
I can buy no more heads so this one has to work !

all exhaust stud holes expanded to m8 by previous person.
Have ordered m8 - m6 exhaust studs (£10) so exhaust fits on easily, another issue he seems
not been able to fix.

So with this bar the missing cam chain guides i might have a complete engine.
Cleaning up the valves ready for reffitting and valve lapping - a pleasant mornings work
and relatively easy.

The forks still have to be completed though !
I can barely wait to be covered in oil again. No matter how hard you try you will
end up swearing and cursing - even with preparation.
The previous owner put them together with missing parts.
 

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Discussion Starter #19
A few pictures , rear bits being put back on and just cleaned the valves up.
When the head arrives then i must decide to aluminium weld a crack on one exhaust
bolt hole or jb weld it. will post pics.

Also cleaning up the sump ready for new gasket.
 

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Discussion Starter #20
Tank now in primer , 1 etch primer coat and rust treated.
side panel - sprayed but cut and polished - no lacquer - awaiting info on a thread for how to do that !
not that i need to but need to on the tank.

cylinder head returns this week from engineering co, fork parts so its back
to mechanics.
 

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