1984 KAWASAKI GPz900R Restoration Project

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Filed Under (Kawasaki) by admin on 01-12-2010

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The paint work on the motorcycle is the original “Red & Gun Metal Grey” but is so badly worn with the outer layer of clear missing and hence all body work requires re-painting. The tank has undergone the usual repair on the left hand side since rust has eaten into the bottom corner from water being in the fuel and the paint has been worn of where the riders legs rub.. The rear tail piece is structurally ok but features worn paint. The right hand side cover has a broken stud and the left hand side cover has a heat warp under the tank. The lower fairing is damaged, the middle fairing is missing one decal on the right hand side and the top fairing has small cracks from a possible accident. The wind screen is worn and faded and will require replacement. The seat has been taped together and requires recovering. Figure 1 Body Work in original state. 1984 GPz900R Schedule of Work 4 of 20 1.2.2 Engine The engine has 90,000 klms on it according to the instruments which appear to be original. The engine was sold with a defective starter clutch as it appears to spin but initial attempts to start the engine failed. A replacement starter clutch is in storage and to refit the part requires that the engine be removed, inverted, bottom engine case removed and all assemblies removed until the starter clutch become accessible rather than a total rebuild. The engine was last run in 2005 and appears to be in good external condition. The condition of the carburetors is unknown but will need to be stripped and cleaned as a service exercise. 1.2.3 Suspension and Brakes On arrival a rust spot with a diameter of 5 cm was noted on the left fork and it was determined that the forks must undergo hard chroming to remove the rust and any chips. The fork seals are damaged but replacements have been supplied. An inspection of the disks revealed worn disks front and rear. New disks are available and will be required. The condition of the brakes appears to be poor but for a bike that has had no services performed this is to be expected. The image below shows the state of the motorcycle at time of purchase

YAMAHA YW50X SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS00022 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.
1-3 GEN INFO IMPORTANT INFORMATION EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. 1 Oil seal c C Do not spin the bearing with compressed air because this will damage the bearing surfaces. 1 Bearing