This is not a restoration. This is a resurrection. I plan to ride Zed, not store it away like a stolen Rembrandt. The front down tubes were pretty chipped and scratched with lots of bare metal so I had to fog a little black paint onto them to slow down the rust. I know all things rust. As soon as ore is melted into steel it begins the long path back to earth. We live in a temporary world; as soon as we stop our struggles and ambitions the things we care about turn into dust. So I painted the Kawasaki’s down tubes.
Next on my list were new steering head bearings. I have a Proto puller set that cost around $150 in 1970 and it mostly is still intact. From that kit I used the bearing separator to get behind the lower stem bearing. I clamped the stem in the vise and a few sharp raps later the bearing was off.
Removing the races pressed into the fork stem is a little harder. There isn’t a whole lot of meat exposed to get a purchase. Some people weld a bead on the race then use that to punch the race out. I’m sure there’s a correct way but I don’t know it so I use two puller claws and force them against each other to wedge the puller tips behind the race. Since you have to hold the claws together with one hand you’ll need a length of old bronze boat shaft to pound on the claws. Most Old Boat Shaft stores carry lengths of bronze shaft. It’s finding the store that’s the hard part.
The new races pop in without trouble. I get them started with a dead blow hammer then finish seating them with a punch worked slowly around the circumference of the race. You can hear the hammer-tone change pitch when the race seats against the frame tube.
The triple clamps were a mess so I wire brushed them and shot some black paint on the things. I’m always aware that any paint work or cleaning I do destroys the originality of the bike so I try to keep it to a minimum. While the headlight ears were soaking in a vat of Evapo-rust I started assembling the forks.
A new throttle/switch assembly from Z1 Enterprises, throttle tube from ebay, throttle cable from ebay, new grips from ebay and somehow these parts from all over the planet fit together nicely. The throttle tube is a bit short and the grip doesn’t quite reach the switch housing but I will be running a NEB cruise control and that widget will fill the space as if it was planned. I think the 90-degree metal bend at the throttle cable housing could follow the bars better but I’m not going to try and bend it.
I’m close to $1000 in parts now. I’m replacing some wear items so I don’t think those should count against Zed.
Want to catch up on the rest of the Z1 resurrection? Just click here!