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Well here it is my first build, a 1981 Kawasaki KZ750e that I bought in from the states along with 7 other bikes
As you do!
W hen I called the guy about it he said in his excited yank voice "Hey man it's not clean bike but it's got a Windjammer III on it"
WTF!!! would you believe it had a 8 track taped inside!

KZ750e the start

Somewhere in Lincolnshire. Grinder.......Hammer.........Windjammer III....skip....Aaaarhhh that's better

Strip one

Next I started on deluging the bike, First off, engine out so I could get around the bike.

Frame without the lump

My idea is that all electrics will sit there under the seat. I did use the stock wiring loom, which fitted, kind of...

Next was the bending of the hoop to form the rear end for the seat and mud guard. The mud guard was off fleebay,Royal Enfield of all things.

Hoop

Mud guard cut down with brackets in place

mud gaurd

Next was the seat pan, I cut the ally plate to shape then bent it to follow the contours of the frame.
I need to give the seat some height so added about 40 mil to the bottom with a upright in place to take the top part of the hump.

seat

I did a quick mock up to get an idea of what the bike would look like, I had some club man bars kicking about so I pop them on and liked the look. Next thing was strip down, final weld up and a flash over with the grinder and off to the powder coaters.

mock up

The engine was in a right old state, there was only one thing I could do .......total strip down.

Grotty engine

I'm not going to bore you with the engine strip down (I've probably done that already) However I will say that when you get to the gear box stage take some photos then take some more. If your doing your own build it may take you a couple of months from strip down to rebuild and believe me they will come in very handy.

gear box

And here we have the finished engine. Looks good?

engine finished

Wheels! The stock spokes were in bad shape, rim and hub weren't a lot better. I got my hands on some stainless steel spokes.

Old wheel

WHAT HAVE I DONE!

I attracted the wheel with a grinder and though what have I done. I've never re-spoked a wheel before in my life. Same as the gear box....Photos photos photos.

what have I done

I made up a frame with a dial gauge and started to dial in the spokes.

Dial gauge

And here are the finished wheels with new boots. Dunlop Road Masters. With a sneak peak of the frame and freshly coved seat!
The bikes in the spare bedroom. The wife is not amused.

finished wheels

Paint next, I filtered and rubbed down ready for the under coat

under coat

Top coat. I spayed the panels with white paint first then applied some fine line tape to get the two strips. A mate of mine from Smudge printed out the Kawasaki on some vinyl, A lick of black paint peel off the stickers and masking tape.....hey presto

with paint

Next a lick of gloss, there was a small amount of orange peel, a bit of 1200 grit and water sorted that.

Glossed

Here we go the build up, I found that placing a frame over an engine is a lot easier than putting a engine in a frame.

engine ready to go

Frame on engine. Simples!

engine and frame

Just about there.

Built up with wheels

Drum roll!!

Here the finished Bike. A not so pretty bike to a little KZ750 head turner.

Kawasaki KZ750 1

Kawasaki KZ750 2

Kawasaki KZ750 3

 


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