Rebuilding a barn find Kawasaki GPZ900R Superbike - Part 3

[@Martin-id6uf]

Please check part availability and price before bringing the big hammer to it. It all mounts up in a big way the costs can go through the roof. The inlet rubbers can be softened with soaking in winter green oil and isopropyl alcohol,this does work. All the best with the restoration.

[@AshRowland]

Thanks mate... I know about the cost, I've just ordered a starter relay for £50!! I've got 2L of IPA on order

[@maltejuergensen2118]

Agreed - as a friend of mine told me on my first bike …… “if it’s hard, stop - you’re doing it wrong” - stand back , think - try again ……

[@paulboag1502]

Rubber inlet mounts and air box rubbers use a heat gun helps with putting the cards back as well

[@AshRowland]

Thanks, I can't believe I didn't think of this to soften them 🤣

[@Brad2meetU]

🙄Not a heat gun but I fell foul of my sister's wrath after I used her Clairol Hair Dryer to help " ease the installation of rubbers on my old bike". Caught out by a small grease smudge on its cable which I missed when removing any evidence of such use, it was the New Year holiday period & she had only just received it for Christmas from Mam & Dad. What a naughty brother I was. 😊

[@AshRowland]

@@Brad2meetU 🤣

[@TheBucksBiker-lh2nm]

Another fine episode... I had to use a massive metal pole to get my carbs off!! As for the throttle cables... Well, that was a flaff in itself that will eventually result in therapy!! Keep up the good work! You're getting there :)

[@AshRowland]

🤣 Thanks mate!

[@francoisscherman7140]

Can confirm that that cable is a pain

[@flibbertigibbet6200]

Fair play to you fella, that bike looks a lot of work to bring that back and restore it and a lot of money too I suspect. And to do it outside at this time of year. Hats off to you, and hope it goes well.

[@AshRowland]

Thank you, I just have to pick a day and cross my fingers with the weather at the minute 🤣

[@JohnWhittaker-j3t]

When refitting carbs use new rubbers and heat gun.Push carbs halfway in and connect throttle cable then push right through.The pipes that you refer to as fuel pipes are in fact water pipes probably fitted retrospectively as a anti carb freezing device.Best of luck most of us have been there at some time.

[@AshRowland]

I did wonder why the pipes connected to the water system 🤣 I've ordered new rubbers for the airbox

[@jeffatkinson690]

Its a bugger fighting rock hard carb rubbers, well done for persevering, read all the comments as someone will have done each challenge before.

[@AshRowland]

Yep, although your comment is the first to mention the hard rubbers

[@markdavies5508]

At least the sun came out the same time as the carbs. God is on your side. 🌄

[@AshRowland]

Its like the world was celebrating 🤣

[@shaunhardie6077]

GPZ900R carbs are about the worst to remove, and even trickier to put back on the bike, you will sharp get to know a lot more swear words before you're done, oh and plenty of skinned knuckles too. The easiest way to remove the carbs it to take out the 2 x10mm bolts that hold the airbox in place, and then push the airbox rubbers into the case, and even then its a "PITA". Throttle cables are easier to remove when the carbs are off the bike then you can dislodge them, also put the cables back on the carbs when you come to refit the carbs. Sorry for the long post but believe me, its for your own piece of mind and sanity, 🤣🤣. Keep up the good work fella, 👍.

[@AshRowland]

I reckon putting them back on will be easy as log as I can fold the rubbers back... pushing the airbox onto the carbs didn't work for me, I guess the rubbers were just too hard

[@shaunhardie6077]

@@AshRowland I've heard quite a few people soak the rubber boots in something called "Wintergreen oil" apparently it softens them up just like new, and they smell nice too, 😁.

[@AshRowland]

mmmmm.... smells nice 🤣@@shaunhardie6077

[@andrewkay114]

Great video, congratulations on getting the cards out, a very frustrating job.

[@AshRowland]

Tell me about it 🤣

[@Tony-ug1mv]

Hi Ash. Total kudos for attempting to strip & rebuild a bike without a shed or garage. 2 questions for you- What’s under the other bike covers & when is your rubbish being collected? as it appears to be piling up☺️ Keep up the good work, looking forward to the next instalment👍

[@AshRowland]

The bin collectors have been on and off striking lately, we're never really sure when they're coming 🤣 the other bikes are my 650 Bandit, Kate's SV650 and my YZF600R Thunder cat... I'll feature them in a video soon, I've done a video with Kate's Brake lights if you want to check that out

[@Tony-ug1mv]

@@AshRowland Thanks for the reply, I’ll check the video out👍

[@alanparis7256]

Hi. Great vid. Those extra pipes on carburettors are coolant pipes. These bikes had problems with carb freezing causing full throttle and deaths . Bikes were re-called and warm coolant tubes added to circulate warm water around the carbs. Regards Alan

[@Gassit]

Yep there part of the carb icing recall. I was working at the dealers when it all went down, must have cost Kawasaki a small fortune as all water cooled and quite a few air cooled bikes had to be recalled. The water cooled bikes got a complete new set of carb with associated plumbing and the air cooled bikes usually got new float bowls with electric heaters below the main jets but even some of those got new carbs too.

[@sjk8273]

My '86 A2 suffered terribly to the point of almost being unrideable. It would splutter and stall rather than anything happening at full chat. The advice at the time was to add a fuel additive from Audi garages. But, I was never notified of a recall by my dealer.

[@AshRowland]

I've heard about this and feel like I need to do some more research, but at the same time wieirdly wish they were the original non-modified carbs for nostaglia purposes

[@AshRowland]

Genuinely really interesting... which carbs do I have?@@Gassit

[@shaunhardie6077]

I removed the whole "Anti-Icing" setup on my A7 and have never had any issues at all with the running of my bike.

[@richardwhelan8060]

Just to mentioned, if you put the screw driver into the head of the screw and bang with a hammer it helps loosen the screw, also bang the head sideways with a flat punch and hammer.. Just an old trick often helps... Where possible use heat and an impact. gun.. Could be a good investment..bty put carbs in a dish full submerged in a parafin for a long as you can before touching them..

[@AshRowland]

I'm scared to use an impact gun on old bolts, knowing my luck they'll just snap

[@richardwhelan8060]

@@AshRowland it's actually the opposite start low torque setting, doesn't work particularly well for rusty screws though. Your side driver is best as you found out.. Good luck with it

[@aciiks]

ALOT easier if you pull the carbs, then yank the cables... The airbox can be somewhat difficult with old rubbers but a decent amount of bad words will solve it :)

[@AshRowland]

Yea I realised that, but I'm not sure the throttle cable was routed in such a way that I could do it that way

[@garryburns6659]

Best of luck with it Mate👍like your videos keep at it👍🙂cheers🍻🍻

[@AshRowland]

Thanks 👍 it always means a lot when someone says that 😊

[@garryburns6659]

Cheers Ash👍🙂

[@damo690]

That was the bolt you lost a day or two earlier. I heard it land on something plastic

[@AshRowland]

🤣 I thought I fished that out

[@mikedavies5084]

Great video ,get some rubber gloves they will save yer hands from getting manky

[@AshRowland]

I keep meaning to... in fact, I'll jump on eBay now and order some

[@johnr4459]

you need a garage or large shed, garages are not for cars these days, they are for bikes

[@chriserskine585]

Be very careful with the oil cooler blots and pipes, so easy to damage them

[@AshRowland]

I've got a horrible feeling that the oil cooler is too rusty to save 😪

[@chriserskine585]

@@AshRowland I had the same with an xj900 needed a new cooler and pipes, couldn't get look a like parts so oem parts were over 500 quid, not good

[@AshRowland]

@@chriserskine585 ouch!

[@ZRXRICK]

Take the WD40 & spray down ALL the fasteners as a starting point, not when you want to actually remove screws & bolts etc. (& trade it in for some AeroKroil)

[@AshRowland]

Thanks, good idea!

[@LeaBrattle-parker-pp5sf]

Wow, you are doing an amazing job. And you sound just like me but you don't swear enough 🤭🤭🤭. My dad had a red and silver one, he says it's the best big bike he's ever owned , he put thousands of miles on his . I'm really looking forward to watching this project progress

[@AshRowland]

Thank you so much, comments like this make it all worthwhile!

[@Oysterseagull]

I would clean the cooling system before you remove the engine. Flush it several times , then add a suitable cleaning product and let it soak for a few days before flushing further. Carb removal is a pain in the rear! Shame the GPZ Zone has closed as they had all the small parts such as rubbers and correct fasteners. The carbs are notorious for leaking and filling the engine with fuel, causing either fuel in the oil via the breather under the carbs or hydraulic lock and a bent con rod when trying to start it. I sold my same colour 900R last year.

[@Oysterseagull]

ps there is a guy in Birmingham who sells used 900R parts. it will help you!

[@Oysterseagull]

pps remove the airbox before removing the carbs. New rubbers will help reassembly.

[@AshRowland]

Top tip, great idea, I want to flush it through anyway... I hope my rods aren't bent

[@shaunhardie6077]

@@Oysterseagull there is no way the airbox will come out before the carbs are out, its an absolute impossibility.

[@medler2110]

The guy in Birmingham is called Sean Jones, he runs an ebay shop, called the GPZ shop and can supply used and new parts. Fowlers do some New old stock parts and there is a Dutch company CMS who do New old stock parts for many bikes, got parts for 80's and 70's bikes from both those.

[@tbr1man]

The screw you found looks like a sidepanel screw. I think you had a non standard one in earlier episode.

[@AshRowland]

I'll look back through, thanks

[@mattsta1964]

You can use Domestos bleach to clean those stainless steel exhaust headers. Just brush it on, leave it for 20 minutes and then wash it off with water. They come up like brand new.

[@terrynicholson9273]

Harpic 10x bog cleaner is the best, nice and thick, blue so you can see where you have covered and has hydrochloric acid in it so stronger than any bleach. Very efficient so wear gloves and only leave it on for 5-10 minutes. Usually in the pound shops and when I see it I stock up.

[@shaunhardie6077]

HARPIC Power plus IS BETTER, and cheaper too, 😉😎.

[@davemonday5381]

If you warm the carb rubbers up with a heat gun. It make the supple. And easier to get on and off. Just saying. If a screw head starts to give, tap it with a toffee hammer it will close up then tap the screw driver in to it. You get a tight fit and the tapping helps too, it works most of the time.

[@AshRowland]

Man, heat gun, annoyed at myself for not thinking of that! thanks mate!

[@liambrady9852]

Are you sure that not the screw you dropped last video and couldn’t find? And you should be spraying all the screws and nuts at the same time with WD when you start the resto to give it a chance to penetrate

[@AshRowland]

Deffo not a screw I dropped 😵

[@justblairthompson]

I have a GPX750 that has the same style carb rubbers. They are hard as nails to get out. I found heating all the rubbers with a heat gun carefully helped a lot Reusing them when they are that hard is possible, especially if you treat them with wintergreen oil. But if you can buy new ones do it. Otherwise you are going to be fighting with vacumme leaks later I am sure someone else has pointed out. Those lines running to the front of the bike are not fuel lines. The carbs apparently had a tendency to misbehave in cold weather. Those hoses are there to heat the carb using the engine coolant.

[@AshRowland]

I'm going to get new ones, I've deffo got a vacuum leak going on 🤣

[@justblairthompson]

@@AshRowland my reply keeps getting deleted, I think because I'm trying to tell you about a website repo rubbers are twenty three dollars for your bike from cruzin image. I got a set for my gpx750 and they were good. They have the air box rubbers too for thirty.

[@AshRowland]

@@justblairthompson if you every have issues with comments you can always email me, its on my channel page and I usually pop it in at the end of every video 😊

[@dartt51]

I would have disconnected the throttle cables at the handle bar end and then just thead them through the frame . I always hated removing the carbs always a lot of bruised and skinned knuckles and profanities that would make a sailor blush my hats off to you for not loosing it. You probably been told already but JIS stands for Japanese Industry Standard. Good vid keep up the good work it always great to see a classic brought back to life.

[@AshRowland]

disconnecting the cables from the handlebars would have been sooooo much easier! haha

[@ZRXRICK]

@@AshRowland The first step for carb removal is taking the front brake lever off. (yes, really)

[@AshRowland]

@@ZRXRICK can you explain this or are you kidding? 🤔

[@ZRXRICK]

@@AshRowland It makes things easier for when you open the throttle housing to disconnect the cables & allows more room for the faffery involved in connecting the cables & getting the housing back together.

[@ZRXRICK]

Just the lever, not the entire master cylinder gubbins etc.

[@bananabrooks3836]

'I think it's an oil cooler' Read the bloody manual that some kind soul sent you ffs. J.I.S. not jis for the umpteenth time.

[@AshRowland]

That manual is hundreds of pages and I have a lazy eye! 🤣

[@johnbleakley9413]

Forgot to mention: these things are 1/2 inch drive, so you can replace the drive bit head with a 1/2 drive socket. Win win. Cheers.

[@tonyfurneaux3399]

Hi Ash, nothing so cool as to watch a guy struggle lol. I would recommend you watch Brick House Rebuilds, BJ has a very brilliant video on Carbs, he does a set from a 70s CB750 it is very confidence boosting and full of good tips. With your bike, I wonder if it would have been easier to get the throttle cable off from the grip end, I say this in case it goes back easier that way. I have a 77 KZ1000 to get stuck into, only 26k KMs on it as I now live in Canada, Great vid, Keep Calm, and Keep Mumbling. JIS Japanese Industrial Standard, a Must have 😁

[@AshRowland]

"keep calm, and keep mumbling" haha made me laugh! You're almost certainly right, there's no way I removed those carbs in the easiest way!!

[@MrChrisallen300]

Them carb rubbers will be an absolute B* I remember many years ago how bad mine were to get back on 🤦‍♂️

[@AshRowland]

So much worse than any other carbs I've ever remmoved!

[@projectclark123]

Really good video

[@AshRowland]

Thanks buddy!

[@andymoorhouse8820]

Hi I am just putting a 1985 gpz900r together got it in bits , theres a guy on ebay selling new rubbers engine side , note there's a mark to show orientation

[@AshRowland]

I've ordered the air box side but couldn't find the engine side so if you could send me a link that would be amazing, email me!

[@JohnWhittaker-j3t]

Yes the two inside are different from the outside two

[@marklapirow5473]

You should get a Vessel impact screwdriver. Mine came, in 1968, with JIS standard "phillips". It is a durable tool. It helps to have a brass mallet, but for years I just used a ball peen hammer with no damage. Otherwise, why don't you get a Milwaukee power driver (hex drive). It has an adjustable clutch, and it is very useful for fairing removals and other light duty work. You can set the torque consistently on fastening bolts / screws too. Also, when you get a work bench, look for a vice and a bench grinder with a wire wheel.

[@AshRowland]

I think I've got one of those somewhere, in a metal tin... I'll see if Makita do one as thats what all my other tools and batteries are

[@Brad2meetU]

I must add (sorry for being such a chatterbox) that removal & replacement of carbs. on the GPz900R was the worst & most infuriating of any of my many bikes, I feared with dread every time, new rubbers, hot water bath helped but that job shattered me.

[@AshRowland]

Yea, the ones on my YZF600R Thundercat just lifted off!

[@TheDavedadd]

Hi Ash, word of advice with situations like that. I have found that when I have had stuck or rounded bolts/screws normally a left handed drill bit will get them out, can normally get them from Screwfix etc.

[@AshRowland]

I'll remember that when I round one off lol

[@robertmaitland09]

My A2 had the water heated carbs, i believe the main jet size was reduced when this was done, might be worth checking it's got the right size. The stainless down pipes and collecters were made by Motad, mine had them with Marshall silencers. Also it might be an idea on reassembly to remove the upper rear engine mounts then remove the front ones and tilt the engine forwards.

[@AshRowland]

Thanks for the tips and info 😃

[@francoisscherman7140]

Excellent video’s every step that you do makes me smile as I have lived every moment of them while working on my own Ninza so many years ago in my 20’s. Those carbs are the worst ever to rake of and needed constant attention. 😂

[@AshRowland]

I agree, they are the trickiest carbs i've ever taken off too, and it didn't help that the rubbers were solid lol

[@projectclark123]

I have shared your youtube channel on my Facebook

[@AshRowland]

You sir are a gentleman! Thank you!

[@projectclark123]

@@AshRowland not a problem

[@SeanieVoiceOver]

3:48 I think you’ll find that’s called a BELLY PAN 😂

[@AshRowland]

Its a weird name for that, let's call it a bib 🤣

[@johnblack9037]

That bike needs a complete rebuilt every nut bolt pipe rubber etc etc etc hats off to you! and doing this without a garage!

[@AshRowland]

Yep, thats the plan 😃

[@peterfergusson2581]

Ash , please dont try and fire the engine without pulling the sump of first, and cleaning it out! Ask me why 😢

[@AshRowland]

Thanks mate, I hadn't even considered that!

[@robrylands1532]

Isn't that screw that went missing from the side fairing you took off in the previous episode lol :)

[@AshRowland]

Dunno, maybe 🤣

[@x-105strikefreedom]

Now rebuilding those carbs is not an easy task, some pilot jets wont come off easily....

[@AshRowland]

I'm hoping they won't be too bad... famous last words eh? 🤣

[@cabbage64]

I'm not mechanical enough to know what you're doing there, but I feel your pain 😂

[@AshRowland]

🤣

[@RichardSmith-yv8pe]

Great project. I would love to restore a classic bike but I have neither the patience or attention span…

[@AshRowland]

It's time I'm struggling with, and weather 🤣

[@kevinpollard1550]

love the vid sir .i have a zzr 1100 every march i release all fixings on fairing and retighten

[@AshRowland]

Great idea!

[@antbailey2648]

its an intercooler already there for the turbo conversion 😉

[@AshRowland]

"holds hand out waiting for turbo donation"

[@MrCamarokid83]

I just subscribed to your channel. I will be following.

[@AshRowland]

Awesome! Thank you!

[@chollythecrazycorgihesinsa6505]

All that hard work will pay off when you ride that nice Kawasaki down the road!!👍

[@AshRowland]

The first ride will be crazy!

[@robertseychell330]

Great video and looking forward to the next instalments. 👍🏻

[@AshRowland]

Thank you so much... spoiler alert, next video is tomorrow at 5pm

[@jomarwilks]

That bolt you found could be from the side panel that had the allen bolt in,

[@AshRowland]

Ahhhh yea! That makes a lot of sense! Well done 👏

[@samh3145]

Don't throw away the old carb clamps just yet Ash, might be harder than you think to source new ones....

[@samh3145]

Ok, CMSNL do still have them...

[@AshRowland]

Good point, the only thing I've chucked is the alarm wiring 🤣

[@millarfamily2474]

I have a little tip that I found by accident - I was using a Bosch 18v cordless drill to remove a few setscrews but I had left the torque setting on about halfway when I was putting a screw IN the last time I used it (so that I wouldn't overtighten it). Most of the screws I was taking OUT came out easily but one was stubborn. What happened then was the torque setting on the drill started to act like a little impact driver - it would apply a little force then disengage, then force then disengage - that shocked the setscrew into moving - Tried it again on a few stubborn small setscrews on an outboard engine and hey presto! Handy little tip - Just make sure the bits are new/sharp. Also remember to tidy up or you'll get Jis all over the place like Ash here🤣

[@AshRowland]

🤣 🤣 🤣

[@millarfamily2474]

If there's two of you, remember never to get your Jis mixed up with another man's - just asking for trouble 😉@@AshRowland

[@AshRowland]

@@millarfamily2474 🤣

[@greengrass9572]

A gubilee clip is ' This Guy' ?

[@AshRowland]

Yea, I was referring to the hose clips on the cards haha

[@Hondakjell2]

Removing carburetors are really hard on old bikes !! Done that 4 times on Honda 750 from the eighties 😢 greetings from Norway 🇳🇴

[@AshRowland]

👋

[@johnbleakley9413]

Hi Ash. I'm watching your issues with rusted in screws. I highly recommend a manual impact driver ( the type you strike with a hammer.) The advantage with these things is that the twisting torque happens at the same time the drive bit is drive into the screw head. No slippage! Best idea since the dung beetle. Cheers.

[@AshRowland]

Yea, I think I've got one somewhere, will have to dig it out

[@therealslimshady4555]

Any time you're lubeing your chain or spraying penetrating oil on your bike always put a big bit of cardboard down it will keep you drive way clean and stain free.

[@AshRowland]

Haha, way to go getting that past the KZbin filters 🤣

[@twowheelsoneleg5672]

I've recently fitted a set of Mikuni flatside carbs to mine so have some carb parts if you find anything nasty

[@AshRowland]

Thanks! I'll let you know 😃

[@roadiesean]

Heya nice looking bike but you could really do with editing your vids more heavily. Nice for you to have a screw by screw reminder but it’s incredibly repetitive I’m afraid

[@therealslimshady4555]

Ack leave cup cake alone he's not doing anybody a bit of harm.

[@AshRowland]

Thanks for the advice

[@mudmucks]

Do we get to see a gratuitous shot of your bloody knuckles after all that? 😀

[@AshRowland]

Don't even joke, they are so mashed up! 🤣