Rebuilding a barn find Kawasaki GPZ900R Superbike - Part 5

In this episode I breath the first signs of life into the GPZ900R in 28 years!
Yes, thats right, I finally get the ignition turned on!
There’s also some bonus footage of my Yamaha YZF600R Thundercat and Kate’s Suzuki SV650
Thanks to Haynes for letting me show you pages from the manual.
Here’s a link to their website where you can buy digital and hard copies of all their manuals:
www.haynes.com
Thanks to Jay-Ninja for the logo, check him out:
• Jay-Ninja | Welcome to...
/ @jay-ninja
Thanks to The Bucks Biker for his tank refurbishment video on his CBR900 Fireblade:
• How to clean a Rusty P...

[@slewisedwards]

Kate is brilliant 😊 We like Kate 👍

[@AshRowland]

Never a truer word said

[@colinculverwell325]

You could try cleaning the starter solenoid terminals. Looks a bit rusty down there. Also the terminal post on the starter. It that don't work you can get it cranking with the quick and dirty trick of bridging the terminals on the solenoid with a screw driver. Make sure there is no fuel around as you will get sparks.

[@AshRowland]

The solenoid started is dead, the coil is open circuit... don't worry, I've sourced a brand new one

[@TheBucksBiker-lh2nm]

Thanks for the shout out mate… I feel very honoured. 😊😊😊 Now I can tell my wife and kids that I’m an influencer 😂

[@AshRowland]

🤣 no worries.... I prefer the term "content creator"

[@TheBucksBiker-lh2nm]

@@AshRowland the wife prefers ‘mess creator’ 😁

[@chollythecrazycorgihesinsa6505]

That was a nice thing you did for that lady👍. Good Karma will come your way!! BTW really enjoying your videos! Keep up the good work!

[@bananabrooks3836]

Yes, a good deed. As well as the warning triangle l would've placed my vehicle behind the subject car(if safe to do so) for extra physical protection from errant traffic.

[@AshRowland]

Yea, I did think about that but it was just off a roundabout and thought an accident was less likely to occur the further away people could see the obstruction

[@kweenie2086]

The mighty thundercat! Have one too at about 65k kilometers and its still starting everytime no issues. In my opinion its an often forgotten bike cuz its always overshadowed by the r6. But the cat sits more comfortable and doesnt have that much less power. Keep an eye on the fuel systems and that thing will run forever.

[@matmiller5256]

Nice one @AR. Keep plugging away !

[@AshRowland]

Thanks buddy

[@twizzlestickx7]

The solenoid just needs terminals cleaning and Vaseline putting on connections

[@AshRowland]

The coil is open circuit and it's a sealed unit... I've ordered a new one

[@phillipparkinson7145]

Yeah! Another episode

[@HalfdeadRider]

You need to find out how to prime the fuel pump on your Thundercat, there are two ways on the old Kawasaki's, one is the easiest and my preferred way, and that is to just holding the clutch lever out around an inch and pressing the starter, you will then hear the pump prime, takes a few goes to get it first time, but turning the engine over brings the oil pressure up which helps also. The other way is with it in gear and the side stand down, and press the starter to do the same. You really shouldn't need to adjust the idle screw, the choke richens the mixture to help the cold start, but it struggles as there is not a lot of fuel left in the system after sitting. I like to run the carbs for as bit with the petcock off so there is less fuel in the system while not being used as it gives the rubber seals etc a longer life.

[@AshRowland]

I think the choke has a part to play in the problem, the slider moves just fine but weirdly it doesn't seem to make a difference to the engine idle, hence why I have to let more air in with the idle adjuster. The fuel pump primes when you turn the ignition on so I usually turn the ignition on and off a few times which helps.

[@HalfdeadRider]

@@AshRowland I had to watch again as I didn't noticer it prime in the video before somehow even though you mention it, otherwise I wouldn't have said what I did 😂 Funny how some carbbed bikes do and others don't, mine is a 2000 E1 model ZX9r, mine would do the same as yours if I don't manually prime it, take time to start and run lumpy and rattly, until it gets more fuel coming through.. Older bikes are still best 👍

[@redmantas9294]

It’s called a starter solenoid the part that’s faulty before the starter 👍

[@AshRowland]

Thanks, I've managed to source a new one, it's on the way

[@georgeday5901]

Theres not many people out there that would help out other people .

[@chrisjeffries8167]

Well done Ash doing a nice job on the bike , but must admit the wife’s bike is better and looks better than the thundercat 😊

[@AshRowland]

I'll let her know... Thundercat is way faster though 🤣

[@chrisjeffries8167]

@@AshRowland lol still prefer the wife’s bike tho 😜

[@alanashley1]

If you like the Thundercat try a Fazer I have an FZ6 Fazer and absolutely love it

[@AshRowland]

They're good fun, basically the same bike

[@alanashley1]

@@AshRowland Mines a bit newer and has a retuned R6 engine in it plus fuel injection

[@katywalker8322]

A lot of jump leads only have a connection on one jaw. Hence if you clamp partly on the terminal and partly on the battery casing (as you had) you might land up with the wired jaw on the plastic casing and no power. That starter solenoid is a fairly basic one. A trigger wire, and earth wire and the 2 main cables, and common to loads of bikes. You should be able to easily find one. For the Thundercat, might be worth checking the valve clearances.

[@AshRowland]

Good point about the jump leads, I didn't think of that, and I've ordered a starter solenoid. I'm going to wait until the Thundercat doesn't start at all before taking it apart again 🤣 Once it's started, after a few minutes it runs like a dream.

[@katywalker8322]

​@@AshRowland I stripped and rebuilt an fzr600 last year. Valve clearances were all over the place, with a couple quite tight.

[@georgeday5901]

Take out plugs then try starter ?.

[@AshRowland]

Thats the up and coming plan 👍

[@twizzlestickx7]

I'm watching this video and saying to myself ffs spray some electrical spray into the ignition ffs

[@AshRowland]

Yea, I was too when I was editing it 🤣

[@georgeday5901]

Whats the other bike?.

[@AshRowland]

My 650 Bandit, forgot to show that one, well spotted 👍

[@Unglandshire]

The number plate light fits below the rear light but above the number plate, if you take your plate off you will probably see the attachment holes.

[@AshRowland]

Ahh, that makes sense! Thanks

[@jn1k203]

Watching from the start of this series, just a tip, you don't need to remove the fuse to check for voltage across it, the tops of the fuses have a small exposed metal contact point that you can get the multi-meter probe onto to test. Good luck with the build, huge undertaking.

[@AshRowland]

Yea, for some reason I forgot about this when making the video 🤣

[@ZRXRICK]

My OCD is screaming that you didn't wash it before you started all this ;)

[@AshRowland]

You're welcome to come round and give it a wipe down 🤣

[@ZRXRICK]

@@AshRowland I'm not exactly in the neighborhood, altho I was just down the road about 33 years ago :)

[@agent010972]

Only one wire goes to one side of the clamp

[@leon0]

I would appreciate it if you could get a bucket of soapy water and a sponge and remove the grime from your Ninja, especially working around the frame. It'll make things easier for both you and your viewers to see what's going on. Also, your bulbs are coming back to life slowly because their contacts will be tarnished and the electrons are having to fight their way in and out. You'll get an instant improvement if you pop them all out and polish the contacts for ten seconds with fine wet and dry. It's satisfying. Give it a go ... 👍

[@AshRowland]

You're not the first person to suggest this 🤣 Thanks for the top with the bulbs 👍

[@Cullz.182]

It's nice to see your making progress. Also good to see I'm not the only one that likes messing about with old bikes. I don't think I could film me doing it tho I swear and curse to much and question what the hell am I doing this for but I carry on anyway the satisfaction of solving a problem is worth it.

[@AshRowland]

Haha, it's quite hard not to curse sometimes, but thats what editing software is for 🤣

[@LeaBrattle-parker-pp5sf]

Those little SV's are amazing bikes I've had two of the later models and that engine is a beast, they handle so well too

[@markwood9755]

This is great stuff, I can’t believe you are attempting this on your drive, however you do seem to be making progress and I am intrigued on how it’s all going to pan out. Thoroughly enjoying every episode and subscribed. Well done for helping the lady out.

[@AshRowland]

Thanks mate! I generally stop for anyone on their own... hopefully it's all going to pan out perfectly 🤔

[@markwood9755]

@@AshRowland I am sure it will and look forward to the process.

[@JoeBlack666]

It's cool to see that you bring back to life old neglected bikes! You have 3 out of 4 main japanese brands. Maybe a birthyear Honda for Kate next?

[@AshRowland]

Ooh, nice idea! I guess she can't moan at me for having 3 bikes if she has 2? 🤣

[@justindoucette1841]

Been watching couple ur videos. I sub scribed only got one question. Why is the horn so important. I been laughing watching. I know he going back after the horn. Why horn matter it’s just positive and make ur own ground lol. Ur fun though bro good videos. The horn thing is too funny.

[@AshRowland]

Haha thanks bro! I get a bit OCD I think and if somethings bugging me then it'll bug me until I sort it out 🤣 I think it's the button that's faulty to be honest

[@justindoucette1841]

@@AshRowland no I laugh cause I wired up custom bike I get it. It’s a small thing but work dammit. Was kinda fun watching someone else’s face just say. Omg why now

[@shaunhardie6077]

The ignition switch is held on with "Shear Bolts" and the hex you see is the remains of the head that shears off when tightened to a specific torque. Its called a "Starter Solenoid" between the battery and the starter motor.

[@HalfdeadRider]

They may be security bolts instead of shear bolts, they used security bolts on the ZX9r. Still may need drilling either way, depending on the state of them.

[@AshRowland]

Probably the same state as every other bolt on this bike 🤣

[@MountainFortyNine]

This is so entertaining. Thanks! 😊

[@AshRowland]

Glad you enjoyed it!

[@dylanbuck1719]

Excellent ,your work is paying of

[@essexhognose1808]

Coming along nicely

[@davidshucksmith3342]

Great series

[@MadOldBiker]

Really enjoyed that episode...every day is a school day..I have never understood wiring diagrams...keep it up Ash...loving this !

[@AshRowland]

Thanks buddy

[@al4904]

Really enjoying following your progress. Way back when I was s young pup I owned a GPZ900R. Awesome bikes from the days when bikes could be super quick without been super uncomfortable.

[@AshRowland]

Thats what I love about the Thundercat, probably one of the last sport bikes that's really comfortable

[@jonsharman6853]

How nice are you, it’s fair to say most people going home would just indicate and pass the broken down car, you’ve definitely topped your pos Karma up, every time you focus on those Gpz clocks I get nostalgic for mine, I’m enjoying this series so much thanks…. p.s We need more Kate on the channel, I think you might be the luckiest man alive, she is right tho, the SV is a great bike 😎

[@AshRowland]

Haha, most people wouldn't even indicate 🤣 Thanks mate, she truly is amazing and very patient with me

[@bananabrooks3836]

I hope your security's good after airing bikes on YT, that and FB exposure notorious.

[@AshRowland]

They all have disc lock motion detecting alarms and they're all chained together. I have a security light and 2 x 24hr night vision cameras. Hopefully that'll suffice

[@cedley1969]

Best thing I ever did to my gpz900 was to fit a gtr1000 front wheel, makes them a lot less twitchy.

[@AshRowland]

I'll bare that in mind, I want to keep it original though

[@marc-dinomeermann7557]

The backside of the fuses are open for measuring. You do not have to remove the fuse. Cheers from Germany

[@AshRowland]

Thanks from Wales

[@twowheelsoneleg5672]

Steady progress

[@andymoorhouse8820]

Ash when you find the paint code for silver and blue please post them because I need the also cheers

[@AshRowland]

From what I can find, Luminous Polaris Blue (635) and Galaxy Silver (611)

[@georgeday5901]

Basicly any 12 v motorcycle starter relay will work.

[@AshRowland]

Yea, but I want this to be a proper restoration so I ordered an original genuine Kawasaki one 💰

[@michaeltruscott9443]

It’s called lithium grease it’s for electric stuff

[@AshRowland]

I call it sticky, slimy, messy, useful gunk 🤣

[@chollythecrazycorgihesinsa6505]

That’s cool that your volt meter is on your speedometer. Wish mine had that

[@AshRowland]

Apparently only the early models had this feature, I think they stopped it at the end of the 80s

[@millarfamily2474]

Love this - really great to see how, as the subscribers rise, then the opportunities rise too - fantastic to see, M8 - long may it continue! 😁 Oh, and real kudos for stopping and changing the lovely lady's wheel for her - It remains to be seen whether you'd have stopped for a middle aged, fat Irish bloke with glasses🤣

[@AshRowland]

👍 Next time I see one I'll stop and give him a lift 🤣

[@millarfamily2474]

🤣🤣🤣@@AshRowland

[@leon0]

I think you would do well to dissemble both the ignition switch and the starter solenoid. On your bike, you have an ignition relay for all things sparky and the starter solenoid (which is just a heavy duty relay) for switching power to the starter motor. I've had trouble with both these before. After seeing your truly excellent work on the fuse box, I'm certain this is within your capabilities. And it will make interesting viewing. The ignition switch is straight forward but assess the guage of the wires that go in and out of it. and decide whether or not they are heavy enough for the full electric load the bike will post through them. I was shocked how thin they were for one of the bikes I own and so replaced with higher rated. The solenoid is trickier because you will have to desolder the thin trigger wires to lift the cap clear. Do this very slowly and note the routing of those thin wires inside the body as you lift the cap. You will find corrosion on the thick copper contacts but can flip them over if heavily pitted. Or do the boring/sensible thing and buy a new one 😄

[@AshRowland]

Thanks for the suggestions... I'll get some contact cleaner down the ignition switch and hopefully that'll sort it out... The Ignition relay in the fusebox is perfect but the starter solenoid is dead, coil is open circuit. I've ordered a brand new one but I will be taking the old one apart to see if I can do anything with it, always handy to have a spare

[@leon0]

@@AshRowland The coils have been fine with my failed solenoids before. They have usually made a clearly audible click when powered on, so the electromagnet side has still functioned. Just so horribly dirty, corroded and burnt internally that they won't pass electricity through the heavy contacts. Yours might be worse than mine have been. It is sensible to replace but yes thanks for agreeing to take it apart. I hope you don't curse me later for having suggested it. I'm really enjoying your project. Thanks again for doing this (filming and editing) so I/we can be there as you go.

[@tomakafrankconlon3207]

That Thundercat is a cool machine. I would say the starting problem is a vacuum leak due to old rubber hoses. Have you got any starting fluid. Best and easiest way to check for a vacuum leak.

[@AshRowland]

Yea, it'll be something like that, but I'm not taking it all apart until it completely stops starting, I've got enough to do as it is 🤣

[@tomakafrankconlon3207]

I know how you feel. I have 3 bikes in my shed that all need attention. Old bikes are like an addiction. @@AshRowland

[@Cochise6-6-6]

Awesome job, wish my wife would ride with me but she despises motorcycles haha.

[@AshRowland]

I need to get an action camera so I can record our trips, but they're very expensive for a decent one

[@Cochise6-6-6]

@@AshRowland Sadly yes, I have a gopro hero 8 black but the battery life is awful and constant errors and over heating issues, I bought a housing to extend battery life, works alright, also I have a high amp charger for bike.

[@AshRowland]

@@Cochise6-6-6 I've heard the DJI ones are a good mid range choice

[@georgeday5901]

Get a decent pair of jump leads first.

[@HalfdeadRider]

He didn't have them connected to the battery properly, it is not the leads.

[@AshRowland]

They were expensive, I was just a moron when fitting them to the battery 🤣

[@richardsouthey430]

Well done ,your hard work is paying off 🙂🙂

[@ZafiraSteve]

Tiny Tim has come such a long way! Just do the voice once, whilst working on the bike 😆 🤣 😂

[@AshRowland]

Just for your Steve... If I remember 🤣

[@Jay-Ninja]

Thanks so much for the mention Ash. Another good episode - Keep em coming.👋

[@AshRowland]

No worries buddy, thanks for the logo!

[@cabbage64]

Good new logo, good on that chap. Good on yourself for the good deed, and good to see the bikes you were hiding. So, what i mean to say is...good. arf. 😀

[@AshRowland]

🤣 all good then!

[@imoldgreg13]

😃

[@mudmucks]

Couple of pointers. As mentioned - they are security bolts in the ign switch - you might have to drill them out. On the fuses, each side of the number are two metal contacts - allows you probe for voltage without pulling the fuse each time :). Finally, pop some strips of rag into your inlets - stop anything falling in there.

[@AshRowland]

Right, I'm hoping I can bang a socket on there... I knew that about the fuses, when I was watching back after editing I though "what a dummy" 🤣 Don't worry, I put rags in there afterwards