By Joe Gresh
The Carrizozo Mudchuckers have too much disposable income. Just in the last few months they’ve bought a Husaberg 400, a gas-in-frame Buell, a KTM 890, and a Kawasaki Vulcan 750. The boys want to do some high speed touring, like going to the Sacramento mile in California, and they are talking 500-mile days in the saddle. As I look over my operational motorcycles I don’t see anything I’d like to sit on for 500 miles. But if I include the non-ops there is one that is capable of reeling off 500 miles without breaking a sweat.
I’m talking about the long dormant Kawasaki ZRX1100. The bike is a road burner of the highest order and looks cool as hell to boot. The only problem is the ZRX has sat for 9 years as CT and I wandered the world. Nothing on the thing works. The last time I rode the bike was on the Christmas toy run in the Florida Keys in 2014. It’s time I changed that.
This resurrection might take a while because I’m knee deep in concrete projects but at least I can start ordering parts as my Social Security checks roll in. I’m starting with the brake systems and forks. The front brakes on the Rex are 6-piston jobs and there are two calipers which means I have to deal with 12 pistons. The brakes are great on the Kawasaki but 12 pistons are a bit much.
Both master cylinders are frozen, probably full of crystalized brake fluid. I’m going to try and get away with cleaning up the master cylinders as I have not been impressed with the quality of aftermarket junk and I don’t feel like looking up a bunch of part numbers on the Kawasaki sites. I mostly stop with the front brake anyway; hopefully that master will be in good shape. A failure of the rear brake won’t slow me down…that doesn’t sound right.
I will rebuild the rear caliper using new seals. Don’t try to follow the logic. In addition, the fork seals need replacing and new fork oil dumped in. I might take a stab at greasing the steering head bearings while the front end is apart.
Due to its long slumber there are many, many issues with the ZRX, like:
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- Cooling system leaks, probably from the water pump
- Broken throttle cable at twist grip housing
- Chain is worn out
- Carbs are gummed up
- Gas tank is full of smelly, gooey gasoline
- Clutch lever is frozen
- Clutch slave cylinder is leaking
- Battery is not there
- Valves need adjusting
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And I’m sure other things will crop up as I get into the project.
I’ve really let this bike down. Believe me, I feel bad about it. Nine years of neglect have taken a huge toll on anything rubber. The good thing is the Rex has relatively low miles (25,000) and has never gone under water so I’ve got good bones to work with. The paintwork is mostly perfect and there are no dents. The bike will clean up and be a stunner. I rode the ZRX from Florida to New Mexico years ago and it will be bookoo-maximus karma if New Mexico is the place where the ZRX1100 rises up to snarl across the rust-red landscape again. Watch this space for updates.
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More Gresh? You bet!
This’ll be fun. I have a set of rebuilt four piston front calipers with new pads that bolt right on to the ZRX. Let me know if you’re interested.
Thanks, Marcus
I’ll keep you in mind if the 6-piston caliper rebuild doesn’t work out.
2 x 6 = 12. Expensive rebuilds on those. If you need pistons it gets worse. Make sure you pump the pistons out as far as you can before you remove the brake lines. I use a stack of paint sticks.
Love these bikes. Hope you succeed in getting it back up and on the road.
Man you love a challenge Joe. Don’t forget to check the tires.
My neighbor and occasional riding partner buys his transportation new, and has good taste in machinery. His new zrx1100 was a stunner and I liked the riding position. After a few years he bought a zzr1200, great machine and price point but a totally different type of ride. He’s had many bikes since, but the ZRX still stands strong in memory. Old school look with new school tech.
Cool! Good luck with it!
The one bike I wish I hadn’t sold more than all the other ones I sold. F the concrete, get the ZREX done!
I sold mine. Cried about it until I bought another.
ZRXOA.ORG. I had an 05 for a number of years, suzuki brake parts for those Tokiko 6 pots are a lot cheaper than mother Kaw, they tend to be a bitch to bleed, reverse filling and using a orbital sander (Sans the sandpaper) on the calipers and banjos help get all those pesky bubbles out, lever hard as a wedding day, um you know what.
That orbital sander idea is cool. I’ll have to try or out.
Yer rear plate bracket is upside down 😉
#61.