Joined after many years lurking

[Robw]

Q

[ADRIAN H]

Thanks for the comments and a week would be impossible for me lol but I am taking my time, I have a Haynes manual but it seems really poor especially the pictures so a link to a better manual would help if there is a better one. some clear assembly pictures would help at basic level especially regarding rear wheel / swinging arm / rear brake - electrics are also going to be a challenge.

Haynes manual is not very accurate. If you want I can email you a Kawasaki workshop manual. Good luck with your project.

[Sparky63]

Hi Adrian,

That would be really helpful if you could. thanks

[sean_rfi]

Hello Sparky63,
I finished an A4 restoration this summer and live in north Essex so could possibly help you if you are really stuck. The Kawasaki workshop manual would be a huge help but also get the downloads on the ZPower website as well - the parts diagrams can really useful.
Sean

[ADRIAN H]

Hi Adrian,

That would be really helpful if you could. thanks

Sent PDF of Manual by "We Transfer"

[Sparky63]

Hello Sparky63,
I finished an A4 restoration this summer and live in north Essex so could possibly help you if you are really stuck. The Kawasaki workshop manual would be a huge help but also get the downloads on the ZPower website as well - the parts diagrams can really useful.
Sean

Hi Sean, thank you for your offer I am in Tendring which is not far from Colchester and 5 mins from Gt Bentley where they do the Weds mass bike meet up, I think that if I can get the bike together then maybe some assistance in getting it running would be priceless. Would like to keep in touch with you if that is ok and also fire a few questions if that is also ok. A couple of questions for the moment - is it feasible to get the engine into the frame and then hook up the electrics, they are in connected to ignition, lights etc at the moment.

Secondly is the best way to get the engine in laying the frame over it on its side or lifting it into the frame in the usual way, weight of course is my concern but also the frame has been powder coated so avoiding chipping whilst lifting in a very heavy engine is important.

One other need is for a lower left exhaust, have the other 3 in fab condition but the bike came to me with an old 4 in to 1 pipe, I know they are rare but anyone with one for sale.... If not a replica lower left might be needed but do they sell them individually?

Thanks to you Adrian for the manual - really appreciate it.

[Sparky63]

So here is the latest headache, I am fitting the rear brake foot pedal, it has a large spring that looks like one end fits into a hole, does anybody have a close up please so I can see its orientation as after two hours I have not worked it out and am trying to protect paintwork.

Engine went in last night and was a surprisingly smooth transition with no damage to the powder coated frame.

One disturbing point - my swinging arm seems very close to the frame midway down the swinging arm, I assume this will lengthen when the shocks are under load?

Also I am struggling to put up pictures and had to put a couple up on an image sharing website but I don't seem to be able to pull the image into my post, I wondered if you had any advice please as I would like to share the progress.

Everyday there are new problems and challenges, today I realised that when I had the frame powder coated I should have protected the shaft that the foot brake pedal sits on, another 40 mins wasted trying to get the paint off so the pedal could slide on but avoiding damage from emery paper. Engine is now spotless and looks great against the black frame.

Going to need some expertise for connecting the electrics, am in Essex in a village called Tendring near Colchester would be happy to give £100 to have the electrics all connected and working, I appreciate it isn't much but if somebody would be kind enough to consider it that would be a great help.

Thanks from the restoration noob!

[warren3200gt]

If your talking about a circular spring with a hook one end and a pin the other I'd guess your working on a 650?
If so it fits on the brake pivot with the hook around the pivot arm before the pivot pushes through the frame. The pin then locates into a hole on the inside of frame brake bracket swingarm side.

[Sparky63]

Hi Warren,

Thanks for the reply

Its a 1976 Z900 A4, I took the pedal off myself so I know it is from the bike its just that it was a few years ago and I have no recollection how it fitted.

[warren3200gt]

Screenshot_20240920_172907_Samsung Internet.jpg (118.61 KiB) Viewed 612 times

[Sparky63]

https://imgur.com/a/ZSiNT0s

Thanks Warren, it looks different or am I just not interpreting the picture.

Not able to work out images but here is the link above

Thanks for your time.

[Sparky63]

https://imgur.com/a/URuWAov

This is how far I have got.

[warren3200gt]

It fits on the inside of the frame. Take the pivot out, put the spring on it, put the pivot back through the frame. Ie spring fits on the inside of the frame.

Screenshot_20240920_174657_Samsung Internet.jpg (118.64 KiB) Viewed 609 times

[warren3200gt]

WGzTVVH.jpeg (148.41 KiB) Viewed 606 times

[Sparky63]

Thanks for your help with this Warren, for clarity does the curly end with your red arrow wrap around the internal part of the frame and the straighter end fit into the small hole in the frame lug?

This must seem laborious but sometimes the simple shit is the hardest to work out, I imagine you are doing this - .

S.