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Project Kawasaki KZ1300

Friday, 3rd June 2016

   

 This restoration is a little different from the XS1 in that we are setting out to transform this weather beaten old 1982 Kawasaki KZ1300 6 cylinder into a look a like 2003 Kawasaki ZRX1200. It will be challenging in many areas but were up for it !!

 


Sitting in the showroom in all its glory. 

Baxter is clearly unhappy with the bosses latest purchase.

13th November 2015    Baxter the company Boxer is clearly not happy with the bosses latest purchase.



Where do we Start !!!!

This particular model the A4 there were only 1800 made worldwide and have quite a few differences to the earlier 79-81 models. Of course all the good bits are gone so the search for parts begin.

 

This old girl has only 3043 miles on the clock.Judging by the date stamps on the tyres and looking at some internal parts we reckon its about right.The aim is to see if we can get her fired up and if can and she checks out ok a motor rebuild is off the list.

PARTS SEARCH

The total ignition system was missing from this bike so we had to source these scarce parts from all over. As there are absolutely zero parts for these 1300s in Australia we found the needed parts in the USA,UK and Japan.

START UP

All wired up ready to see if she will start up. With this one having 2 stators,2 voltage regulators,3 coils, resistor coils and two ignition switches its been a bit of headache getting the wiring sorted.Hopefully all the connections are right and she lights up.  

She's alive at last,fired straight up, no smoke and sounds great.

 

ENGINE REFURBISHMENT

 After the motor was started and run it was removed and was all sealed up ready for bead blasting. When this was done the motor was painted in high temp black paint.

 All the covers removed for chroming. Most of these covers were originally chromed in the factory and they certainly show their age.Qld Chroming took care of this and they come up great.

The motor looks great all painted up with the freshly chromed cases bolted on.

WHEEL REFURBISHMENT

The old wheels were sent to DEPULU WHEELS at Ashmore Qld for a complete transformation.They did a brilliant job of machining the wheels and then finishing in 2pac gold.

FRAME FABRICATION

To take on the ZRX bodywork the frame needed various brackets added to suit the tail and seat and modified tank mounts to accommodate the ZRX tank. Lindsay Donai once again helped out with some nice neat welding.

POWDER COATING

The frame and various components were taken to Roberto's Custom Powder.We would not trust anyone else to powdercoat the frame as Roberto knows exactly what goes into one of these restorations. The finished frame and components fit together nicely with all threads and bearing surfaces masked up for easy installation.We are doing this one in Roberto's satin black and as always it has come up beautifully. Thanks for another fantastic job Roberto.

FRAME ASSEMBLY

Now we have the frame back we can set about piecing it all together again.Its starting to look like something now, just waiting to mount the big 6 in place.

MOTOR INSTALL

The motor went in reasonably easy the extra man lightened the load of the big six. We had to remove the sump to get it in. Gee that motor looks the goods. Now the fun begins with the electrics.

ELECTRICS

As we are using 2003 ZRX switches and gauges etc its a bit of a job marrying up the old 1982 wire harness with the later stuff.Its taken a lot of time with two different wiring diagrams to try and figure it all out. 90% done just a few issues left to solve.

Surely this bike doesnt need all this wiring, Id like to cut half of it out but which half do you cut?

 

Fan and radiator in place

BRAKE UPGRADE

The ZRX had 6 piston calipers which look great and should help pull this beast up.New EBC rotors front and back fitted and using the standard caliper on the rear. All painted to match the wheels by Bob at Ace of Sprays.

SPRAY PAINTING

This part of the restoration is taken care of by "Bob at Ace of Sprays" at Redland Bay. Bob painted the XS1 for us and I know he will turn out another perfect spray job for the 1300.

 
   

 

       

 

Base coat on and looking great.

Next the Metallic Silver stripes applied and they really sparkle.

Another brilliant paint job thanks to  Bob at "Ace of Sprays" at Redland Bay, Brisbane. The before and after shots tell the story. I can highly recommend Bobs work, if you need any motorcycle painting Bobs the man to see. You can contact Bob on 0466 842 679.

Thanks Mate.

Bolting up the bodywork, looking flash as.

New Badges made to suit by Mastercut at Burleigh Heads Qld.

Wow,I love it!!             Lindsay taking the 13 for a squirt                                                                                                                        

 

Well,15 months after buying the bucket of bolts its finished.It is simply a beautiful bike.It will be on show at this years Ray Owen Classic at Canungra Showgrounds Qld on the 7th of May. Come and check it out and say hello.

 

A BIG thanks to all that had a part in this restoration,I can highly recommend all of these people to take care of any restorations you may take on. Thanks to one and all.

Spray Painting ~ Bob at Ace of Sprays  0466 842 679

Powdercoating ~ Roberto’s Custom Powder 07 3899 9832

Mechanic and go to man Lindsay Donai  0427 027 774

Front end engineering ~ Dave Kellett 07 3290 2811

Wheel refurbishment ~ Depulu Wheels GC  07 5597 3891

Chroming ~ Qld Chrome Tingalpa  0401 961 811

Seat manufacture ~ Steve Broberg  0418 758 277

And EBAY