Bringing an E1 back from the dead

[LondonZ1]

The finished bike will not be totally original. It has a lot of subtle upgrades to make it everyday usable. Modern Bosch fuel pump and FPR, Wilbers rear shock, braided brake hoses, anti-dive blocked off, upgraded alternator, MOSFET regulator/rectifier, lots of stainless fasteners especially where corrosion is a problem. It will have a set of Malcolm Cox silencers and a Cox H-pipe which I have had black ceramic coated for durability. It will however look original with standard paint and bodywork but with a US rear fender. I am so looking forward to getting the engine in!

[longfiredragon]

Just catching up here Pete. Your doing good. It took me just shy of seven years to finally pull mine of the shed running for the first time.

Engine looks awesome, can't wait to see it all done.

Stay with it

[gpzrfan]

Pete, your the no 69 bus ...... you don't see it for ages, every one begs for an input... nothing for years ( at least one) ..... and then you get lucky and it delivers !!

Pics are great, love the finish on the engine ......

[LondonZ1]

Today the restored engine finally went in the frame. Everything went smoothly and Jeff and I got in it without any damage to engine or frame. The sump still has to go on and I have to fit the restored generator and ignition covers. Plus break the chain, thread it round the front sprocket and fit the sprocket cover. And lots of other things like connecting the electrics, changing the front master cylinder, fitting the throttle bodies and plenum chamber, exhaust, oil cooler, fuel lines, starter motor, fuel pump....

These are all fairly simple, just time-consuming. And getting the engine fitted is a huge motivator. I'll take more pics as it comes together.

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[Charlie @ Evergreen]

Looking lovely! Can't wait to see her dressed up and running

[longfiredragon]

Nice, very nice. Yep all that little stuff is time consuming.

[Kawadoodle]

Looks great. It's so rewarding when it's all coming back together. When finished you kind of miss it.

[georgew4714]

Looking great

[LondonZ1]

I am making some good progress. It's very satisfying assembling clean restored parts compared to the grief of disassembling a rusty mess. Chain now on both sprockets and adjusted, fuel tank tap, sender and return valve in place, ECU installed and connected, timing cover fitted, spark plugs and coils fitted, oil sump and filter installed. Next up is the fuel tank display, install the fuel pump and throttle bodies, run the throttle cable, connect the switchgear, torque up the alternator rotor, fit the spider pipe and turbocharger...and lots of other jobs too.

I am encountering some problems en route but nothing major so far. I fitted a US front brake master cylinder by mistake which will need to be changed for a European one. Luckily I have several spares which are off for cleaning before being painted and fitted with all new parts.

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[LondonZ1]

here's the underneath of the fuel tank with NOS fuel tap, sender and non-return valve.

[riturbo]

Looking great

[LondonZ1]

I've been working on the wiring and it has been going well. Almost all the electrical system is new including both main harnesses, fuse box, switchgear, indicators, rear light, stator, reg/rec etc. This means that it's all nice and clean and the connectors have no corrosion. It's a very tight fit and I think I will leave out the tool box to make more space for the wiring. The main (non-DFI) harness is brand new from Japan. The guy who makes them is a craftsman, all the right wire colours and connectors but he uses slightly thicker gauge wire. This makes the harness a little stiffer and bulkier, another reason to ditch the toolbox.

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[LondonZ1]

This is the instruments and handlebars. I managed to find NOS switchgear, the bars have been black zinc plated and the yoke and clamps powder coated. The gauges are original but with a NOS top cover. The bike had been stored indoors so the colours haven't faded. I think the milage was genuine. Grips and bar end weights are also new. I haven't fitted the warning light assembly yet as I need 1) some M3 self tappers and 2) some of the little illumination lamps. Anyone know where I can buy new lamps? You can still get them from Kawasaki for £3 each which seems extortionate.

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[LondonZ1]

There are two leads I could not locate in good condition: the battery main power and earth leads. These are unique to the turbo as they have extra feeds for the DFI harness. I think I'll just make new ones that won't look original but will do the same job. The power lead is actually quite tricky to make as it has four output wires in a short harness.

The bike has a modern Bosch fuel pump and I made a little lead so it can connect straight into the loom.

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[LondonZ1]

next up is to rebuild the starter motor, fit the whole throttle body/plenum chamber assembly and test that the electrical system actually works.