Well I ended up buying the brake seal bits from my local Kawasaki dealer, price worked out to be about the same as buying from ebay O/S so decided to stay local and I have started the caliper clean up. And a few other bits done, motor is back in, seats recovered and muffler polished.
So its been a while but progress has continued, recently bought some new tyres for the old girl some nice Dunlops, I also bolted the old yellow fairings back on just for a look as I had never seen it all complete. With the bike recently running I found it has a nice leak from the oil pump so I have just stripped that down, I was able to get the oil pump seal, water pump gasket and water pump mechanical seal kit from Kawasaki but had to go to grey import for the oil pump O ring, hopefully I will have that rebuilt in the next week. My recent trolling of gumtree I managed to pick up some replacement fairings and fuel tank for a fair price as mine had seen better days, Im just doing some tidy up work on them now the colour scheme is definitely a change from the yellow, hopefully it will be on the road soon.
If anyone a spare new oil pump O-ring or knows where I can get one in Australia I would be keen to buy one, I had one on order but have just be informed it's an 8 week wait. Part number is 92055-1437
Yeah I got it sorted out today thanks, started the bike up and no more oil leak which is nice. I spent the afternoon rebuilding fuel tank locks and trying to make up a decent front brake lever that works properly, I bought a new front lever from motorcycle spares warehouse but the part of the lever that pushes on the master cylinder pin is to short which allows the lever to travel to far, if I can't get it the way I want I might have to go genuine.
More progress today, worked on fitting up the fairings, I have to say for a 30 year old bike that's probably been dropped more times than I want to know it was a real challenge to get everything lined up. I managed to get every rubber and clip from Kawasaki to make this all go back together, wasn't cheap but at least it is done properly. Still plenty to do before rego but it's progress.
Beautiful job. I agree purchasing all of new rubber parts does add up fairly fast. But at'least you've done it correctly and it will last.
I used an ultrasonic cleaning tank set a 60deg c with a mix of water and simple green, it came up almost like new.
So in my search for inlet manifold number 4 on the second hand market, I got offered a "good used" one for $120 on FB and then found a whole head with all four inlets for $80 so I snapped that up today from the local cash and co motorcycle wreckers. I have pulled the manifolds off to come across a possible cause of my idle issues, was interesting to see that all four were the same on the spare head and I bet my bike has the same issue. It appears with age the rubber seal has shrunk back providing no seal as can be seen with a straight edge across it. Anyone else seen this issue?
The flattened o-ring there is what seals the whole manifold. I'd say those are no good unfortunately, but having a head for spares is always good. The manifolds on my C model all had leaks around the vacuum ports, new ones cost about $100 for a set. You can see they are numbered #1 #2 #3 #4 for each cylinder, all that really changes is the little index to hold the clamps in the right position so they don't spin when tightening/loosening. It's also common for the inside surface not to perfectly match up with the casting on the inlets, so they can be taken to with a dremel etc to get them perfect. Same deal with the trumpets on the airbox side.
I'm thinking about making some gaskets to seal it up, I haven't seen a set of new inlet manifolds for $100. Interesting about the leaks around the vacuum ports, I will check these ones over. I'm going to have to work with what I have for the time being as I just spent my play money on new tyres for my ninja 1000.
Now that is interesting. If that is the case then it might be worth making some. You can buy new ones from Impex for 16 USD. I will put one on my shopping list for medical experiments. Except mine would have a replaceable o-ring groove.