Page 1 of 2 12 LastLast
Results 1 to 20 of 24

Thread: Restoration of 1989 Kawasaki GPX 600R

  1. #1
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15

    Restoration of 1989 Kawasaki GPX 600R

    Hi Guys,

    I am new to this forum and just wanted to introduce myself and my current resto.

    I have been riding bikes since I was 10, road/trail and have been riding mainly a 1988 Honda VT250F that I did a full restoration on back in 2006. That bike has since been sold and am now working on restoring a 1989 Kawasaki GPX 600R that I picked up for cheap.

    Click image for larger version. 

Name:	20170607_220354.jpg 
Views:	1 
Size:	85.2 KB 
ID:	8039

    I got the bike about 6 weeks ago and have been assessing what I need to complete the resto. Mechanically it is in pretty good nick though it was sitting outside in the weather for a few years and not started for just as long. It looked an utter mess and thought I would be in for a can of worms.

    When I picked up the bike the clutch would not dis engage when in gear, not an UN-common problem with a wed clutch.

    After dropping the old (Very Old) oil and water, flushed the system and charged the battery, filled with fluids and discovered an electrical problem. I thought that the wiring loom was cactus due to its age and storage. Only 10k on the clock (Not sure if its gone around) Multi meter out and found that there was a loose connection on the ignition switch. Re-soldered and starter would turn over, though the fuel tank was full of rust so off came the tank and all the fairings.

    Click image for larger version. 

Name:	20170626_034049.jpg 
Views:	1 
Size:	88.8 KB 
ID:	8040

    Feed fuel to the carbs and turned it over. Wouldn't start but fired a few times, checked the choke and the lever was missing so manually pulled the choke rail on the carbs and she fired up. No knocks running smooth once warm, though once the cooling system pressurized the radiator leaked like a sieve..

    Found a radiator on eBay in the US for a good price. Came 2 weeks later which gave me some time to strip the bike and clean it.

    The radiator arrived today! No leaks so pretty happy with that. Filled and started it up, came up to temp and let run for about 20 mins. Unexpected thing happened, the clutch was working now so I decided to take it for a quick test ride (On a property so all legal) Gears were a bit still but loosened up after a few changes up and down.

    Click image for larger version. 

Name:	20170626_034108.jpg 
Views:	1 
Size:	86.3 KB 
ID:	8041

    The front brake master cylinder was seized, found a replacement on Gumtree for less than a re-build kit. Hope it gets here soon. The drive chain is covered in surface rust and all the rubber o rings between the links were brittle so have to find a new chain as well, should be one on eBay.

    Now that the bike is running and I know what I need to get it running and roadworthy I am turning attention to the fairings, choosing a color scheme that is a bit brighter than the plain black, grey and white. Thinking about blue, white and red with a new set of decals off eBay. I want to keep the design close to the GPX of its day so it will take some time to get it right. I have seen a 1989 GPX online that I like the look of and will go with something similar to this.

    Click image for larger version. 

Name:	1989 Kawasaki GPX 600R.jpg 
Views:	1 
Size:	19.8 KB 
ID:	8047

    You can see the fairings are in a terrible state though they are mostly complete with little cracks to be repaired. Next step to sand back all the paint and prep for painting.

    Click image for larger version. 

Name:	20170626_040240.jpg 
Views:	1 
Size:	90.3 KB 
ID:	8042Click image for larger version. 

Name:	20170626_040301.jpg 
Views:	1 
Size:	78.9 KB 
ID:	8043Click image for larger version. 

Name:	20170626_040336.jpg 
Views:	1 
Size:	83.1 KB 
ID:	8044Click image for larger version. 

Name:	20170626_040418.jpg 
Views:	1 
Size:	86.1 KB 
ID:	8045Click image for larger version. 

Name:	20170626_040504.jpg 
Views:	1 
Size:	84.8 KB 
ID:	8046

    I will post more as the project progresses. Please feel free to comment, I would appreciate the feedback!

  2. #2
    Bloke with the stick Gix11's Avatar
    Join Date
    Jun 2003
    Location
    Gold Coast, Queensland, Australia
    Posts
    17,574
    Blog Entries
    34
    Absolutely awesome first post mate!

    Welcome aboard.

    All new posts have to be moderated due to spammers, so sorry for the delay.

    Cheers mate.

  3. #3
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Thanks mate,

    More to come!!



    First startup with radiator replaced.

  4. #4
    Bloke with the stick Gix11's Avatar
    Join Date
    Jun 2003
    Location
    Gold Coast, Queensland, Australia
    Posts
    17,574
    Blog Entries
    34
    Great stuff mate. Keep it coming as I love these restoration threads. I had a go on a GPX600 back in the early 90's, so I know they are a bit of a gutless pig, BUT, with that in mind, it proves you are all about the fun of the restoration process, at a price that is right, and I really admire that passion. Good stuff and cheers again.

  5. #5
    ASF Premium Full Member LKC73's Avatar
    Join Date
    Nov 2007
    Location
    Sydney, NSW, Australia.
    Posts
    1,507
    This looks like it will be a cool resto, good luck with it and plenty of pictures mate
    Monster GSXR 7/11 RIP!
    Raven R1 Demon.
    K7 750 German Style (under construction)

  6. #6
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15

    Thanks

    Thanks guys, Ill keep you posted with more pics and video's as the resto progresses. I'm still waiting on some parts so will try to get some more up in the next weeks.

  7. #7
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Quote Originally Posted by Gix11 View Post
    Great stuff mate. Keep it coming as I love these restoration threads. I had a go on a GPX600 back in the early 90's, so I know they are a bit of a gutless pig, BUT, with that in mind, it proves you are all about the fun of the restoration process, at a price that is right, and I really admire that passion. Good stuff and cheers again.
    Cheers mate, yeah its a bit gutless stock, after the resto and get it on the road I'll be looking at getting a few more HP out of it, I would appreciate some tips on doing this.

  8. #8
    Bloke with the stick Gix11's Avatar
    Join Date
    Jun 2003
    Location
    Gold Coast, Queensland, Australia
    Posts
    17,574
    Blog Entries
    34
    Yea, of course. Don't expect miracle power increases, but you could definitely get a few HP from a new can, air filters and re-jetting.

    Somebody started playing with one of these a fair few years back, but you might find this topic interesting all the same: http://www.streetfighters.com.au/for...ighter-project.

  9. #9
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Quote Originally Posted by Gix11 View Post
    Yea, of course. Don't expect miracle power increases, but you could definitely get a few HP from a new can, air filters and re-jetting.

    Somebody started playing with one of these a fair few years back, but you might find this topic interesting all the same: http://www.streetfighters.com.au/for...ighter-project.

    Thanks for that thread, looks like he was having a lot of trouble from the get go as it was a project in progress. Luckily mine runs well, surprisingly well and will run a bit better once I have welded up the crack in the exhaust.

    Just pulled the rear wheel of and chain. re packed the bearings ready for the new chain to come. Got everything I need now to strip the fairings down and prep.

    From others trying to get more out of this bike with pod filters and re-jetting seems like a nightmare, so I'll keep you posted what I'm going to do. Definitely starting out getting it stock for RWC, no oil leaks which is a bonus.

  10. #10
    Bloke with the stick Gix11's Avatar
    Join Date
    Jun 2003
    Location
    Gold Coast, Queensland, Australia
    Posts
    17,574
    Blog Entries
    34
    Any bike of that age with no oil leaks is a bonus! Yep, keep us updated mate. Cheers.

  11. #11
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15

    Resto Update

    Hey guys,

    Pulled the rear wheel off to remove chain as it is stuffed.. All the o rings have perished.

    Click image for larger version. 

Name:	20170716_111424.jpg 
Views:	2 
Size:	78.8 KB 
ID:	8101

    Front master brake cylinder arrived yesterday. The one on the bike was seized and the top cap screws were threaded to picked on up cheap on gumtree.

    Click image for larger version. 

Name:	20170716_111441.jpg 
Views:	1 
Size:	75.7 KB 
ID:	8102
    Old master cylinder

    Click image for larger version. 

Name:	20170716_111435.jpg 
Views:	1 
Size:	86.4 KB 
ID:	8103
    replacement master cylinder

    When I pulled the rear wheel off I discovered a lot of old chain oil and garbage in the drive sprocket area. Gave it a good clean, still needs more DE-greaser and some elbow grease. Have soured a new chain off eBay for $55.

    Click image for larger version. 

Name:	20170716_111424.jpg 
Views:	2 
Size:	78.8 KB 
ID:	8101Click image for larger version. 

Name:	20170716_111518.jpg 
Views:	1 
Size:	80.4 KB 
ID:	8104

    How does the sprocket look? Do you think I should get a new one??

    I have found brake pads though I am still looking for a choke lever for the (LH) lights array as the lever has broken off at some stage.

    If anyone has one lying around or is willing to take it off a spare I will buy it. Thanks guys.

    Click image for larger version. 

Name:	20170716_111458.jpg 
Views:	1 
Size:	77.0 KB 
ID:	8105Click image for larger version. 

Name:	20170716_111509.jpg 
Views:	1 
Size:	74.7 KB 
ID:	8106

    Pics of the (LH) lights array. I have found someone who has the entire unit though is in worse condition than mine and just want the lever. It's not warm enough in winter to start without the choke.

    More to come and would be great for any advise, comments or parts

  12. #12
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Also need a Petcock as well. I've seen rebuild kits on eBay, has anyone had experience putting a kit on these? Whay success have you had with getting one working again?

    I found one for sale complete in the US though is $150+ postage (Rip off)

    The tank was full of rust. Filled it with 12L of vinegar and left it to sit for 2 days, added a heap of nuts and washers into the tank and gave it a good shake around every few hours. After I got the vinegar and nuts and washers out (took forever....) the tank was rust free! Cost about $9.50 for vinegar so was a very cheap way to fix the tank.

    Click image for larger version. 

Name:	20170716_114434.jpg 
Views:	1 
Size:	76.4 KB 
ID:	8107Click image for larger version. 

Name:	20170716_114459.jpg 
Views:	1 
Size:	78.8 KB 
ID:	8108

  13. #13
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Another question.

    Has anyone had to bleed the brakes on a bike with AVDS (Anti-Dive System)? When I put the working master cylinder on I am going to have to bleed the system. Ive done this on cars and my old honda though they never had this system. Is there any tips or tricks to it?

    Click image for larger version. 

Name:	20170716_115232.jpg 
Views:	1 
Size:	81.4 KB 
ID:	8109

  14. #14
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Quote Originally Posted by Gav89GPX600R View Post
    Another question.

    Has anyone had to bleed the brakes on a bike with AVDS (Anti-Dive System)? When I put the working master cylinder on I am going to have to bleed the system. Ive done this on cars and my old honda though they never had this system. Is there any tips or tricks to it?
    All good, got the replacement master cylinder on and bled system. Seems to be holding good pressure and the AVDS is stopping the forks from diving when I apply the brake and push it down.

    Click image for larger version. 

Name:	20170716_190420.jpg 
Views:	1 
Size:	79.9 KB 
ID:	8110
    Replacement master cylinder. Sanded back the embossed lettering to tidy it up a bit, will probably spray it when I get to that stage.

    Just need to work out if I keep the AVDS or scrap it as others have posted on various other forums. Apparently the bike performs better without it??? Does anyone have a bike with anti dive system, and how do you think it performs for you? Already got original AVDS decals for both forks but don't care if I've wasted $15 on decals if the handling is better with the system removed.

    Any thoughts?
    Last edited by Gav89GPX600R; 16-07-2017 at 07:08 PM.

  15. #15
    Bloke with the stick Gix11's Avatar
    Join Date
    Jun 2003
    Location
    Gold Coast, Queensland, Australia
    Posts
    17,574
    Blog Entries
    34
    Everyone I know that had the old Anti-Dive mechanism has updated their forks anyway, so I can't really say that the system is good or bad, it's just kinda there with that model bike!

  16. #16
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Sanded back fairings and tank lightly ready for wax and grease remover and then respray.

    Click image for larger version. 

Name:	20170717_114529-min.jpg 
Views:	1 
Size:	87.2 KB 
ID:	8118Click image for larger version. 

Name:	20170717_114535-min.jpg 
Views:	1 
Size:	85.3 KB 
ID:	8119Click image for larger version. 

Name:	20170717_120207-min.jpg 
Views:	1 
Size:	88.1 KB 
ID:	8120Click image for larger version. 

Name:	20170717_120210-min.jpg 
Views:	1 
Size:	89.5 KB 
ID:	8121Click image for larger version. 

Name:	20170717_114518-min.jpg 
Views:	1 
Size:	85.8 KB 
ID:	8117

    Going to get some plastic rejuvenation for the lights and other plastics.

  17. #17
    Bloke with the stick Gix11's Avatar
    Join Date
    Jun 2003
    Location
    Gold Coast, Queensland, Australia
    Posts
    17,574
    Blog Entries
    34
    Good progress mate!

  18. #18
    ASF Premium Full Member LKC73's Avatar
    Join Date
    Nov 2007
    Location
    Sydney, NSW, Australia.
    Posts
    1,507
    Looks good mate, its a bit of work involved in resto of a full fairing bike. Keep up the good work.
    Monster GSXR 7/11 RIP!
    Raven R1 Demon.
    K7 750 German Style (under construction)

  19. #19
    Pizza delivery boy/girl
    Join Date
    Jun 2017
    Location
    Queensland Australia
    Posts
    15
    Cleaned fairings with wax and grease remover and sprayed with primer.
    Click image for larger version. 

Name:	20170720_093601.jpg 
Views:	1 
Size:	88.9 KB 
ID:	8139Click image for larger version. 

Name:	20170720_093605.jpg 
Views:	1 
Size:	89.7 KB 
ID:	8140Click image for larger version. 

Name:	20170720_093609.jpg 
Views:	1 
Size:	85.2 KB 
ID:	8141Click image for larger version. 

Name:	20170720_093621.jpg 
Views:	1 
Size:	77.3 KB 
ID:	8142Click image for larger version. 

Name:	20170720_093903.jpg 
Views:	1 
Size:	91.3 KB 
ID:	8143
    2 more main fairing to go and then I'll be ready for color. Let the fun begin!
    Attached Thumbnails Attached Thumbnails 20170720_093903.jpg   20170720_093601.jpg   20170720_093605.jpg   20170720_093609.jpg   20170720_093621.jpg  

    20170720_093601.jpg   20170720_093605.jpg   20170720_093903.jpg  

  20. #20
    Bloke with the stick Gix11's Avatar
    Join Date
    Jun 2003
    Location
    Gold Coast, Queensland, Australia
    Posts
    17,574
    Blog Entries
    34
    Nice. You going to do all the final colour painting yourself as well?

Page 1 of 2 12 LastLast

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •