From a $200 purchase from a mate, Pushed into the shed and stripped down of all plastics. Degreaser and pressure washer as had been a greasy dog kennel for several years.
1. Pulled the plugs and had a look, oily but not wet considering it had sat for 5 years.
2 Pulled the carbs and started labelling all the bits and cables.
3 Stripped and cleaned the carbs, two smashed float, replaced
4 bought new battery and went to start it, repair corroded broken wires in RHS controls, fix that, and kill switch that broke while working on starter button.
5. Did compression test -1&4 ok, 2 nearly nothing, 3 not much better than 2.
5a. Dropped oil in the bores, went to crank it and do retest, found negigable change which was pleasing.
6. pulled the head and stripped out all the valve springs, measured to spec.
7. Stripped the head and re-did the valves, bought replacement head from Sean and stripped that, tested all valves on dial guage rig I made up, less than half of the originals were ok, some bent or heads out of round.
8. Assessed and sorted all valves and springs, checked all rocker arms and cams for wear, all seem ok, no scoring etc.
9. Made new head gasket from .6mm annealed copper sheet and Hylomar
10. re-assembled head and lapped all 16 valves, leak test with kero in inlet and outlet, redo 2 lappings, retest all ok.
11. Made pressure test rig and bolt up to head to check leakage under pressure, all checked ok.
12. Clean down block and piston crowns, polish with 1200wet and dry with oil,
13. Re-assemble head to block and torque down. Re-assemble all ancillaries.
14, check timing, reset gap on crank pick ups,
15. Compression check again, yay, all 150psi plus, Win
16. Rebuild carbs and assemble onto bike, made test tank from lawn mower fuel tin. Bought and installed 4 x unifilter 60mm pods, in red of course.
17. Attempt start, oops no mufflers cause they get in the way of work, sorry neighbours.
18. Restart with mufflers, idles but wont rev past 3000
19. pull carbs again and put overhaul kits through them.
20. Balance carbs with diff. pressure guage and SWMBO vacuum cleaner, using a home made 2-1 adaptor, carbs balanced with .3 kpa of each other, Google Dwyer Magnahelic.
21.Carbs back on bike, now revs better but not great, to 6000.
22. Replace all leads and plugs, making sure non-standard leads actually make it to the plug terminal, and seal the well at the same time.
23. Re-install tank onto bike and fill will 10L of 98oct.
24. Starts after about 6 attempts with tap on prime.
25. Rebuild tap with overhaul kit, now pump works.
26. tank back on bike, starts easy runs well for 2 minutes then coughs and dies.
27. Pop lid of tank to relieve pressure drop, remove cap assembly after carefully dropping one lid bolt into tank
28. Rebuild cap with new gasket and clean out breather passages, reclaim bolt and re-assemble lid.
29. Tank test with spare hoses and sucking on vacuum port hose. Reserve flows but no main.???
30. Discover that in 13 months, A LOT of fuel has evaporated or disappeared somehow, leaving not enough fuel for the main port.
31. Another 10 litres of Saudi's finest and we are a happy GPZ900r ready for rego tomorrow.
Oh by the way, in between time I replaced the tank with a straight one,thanks Steve, and fixed, bogged, sanded, primed, sanded and top coated all the plastics.
Also replaced the fuel filter, oil filter, oil, bled the front brakes, replaced all pads, stripped and rebuilt the clutch basket and plates, freed up the frozen brake pistons, cleaned the chain and soaked it in oil for 2 weeks. replaced the front brake switch, several bulbs, tightened up the sloppy controls and generally cleaned the beast up.
I sure there is more but I am tired and need a beer.
throw a few pics so we can see if its as good as it sounds
but theres no point going crook cause has i have learnt it doesnt fix the problem,hope you didnt do to much damage to your bike
