ZRX RX: An ExNotes Resurrextion, Part 2

By Joe Gresh

This ZRX1100 resurrextion started out kind of leisurely. We don’t like stress at ExhaustNotes.us because we are at peace with our surroundings. ExhaustNotes staff have a firm grasp of our place in the universe and see all matter as insignificant much like we see ourselves. There was no big rush, you know? However, things change in life and the ZRX resurrextion timeline has sped up due to the Mud Chuckers wanting to attend the road races July 7-9 at Laguna Seca in California, now known as Polident Speedway. From my house to Laguna Seca is 1150 miles the fast way and we never take the fast way. We might end up doing 2500 or more miles round trip. Thus, the urgency to get the road burner running as none of my other motorcycles are exactly suited to the job.

The first thing I did to the ZRX was to remove as much bodywork as possible to prevent the odd dropped wrench or spilled brake fluid from damaging Rex’s somewhat pristine original paintwork.

Kawasaki ZRX1100 bits and pieces have been trickling into the shed at Tinfiny Ranch and we will soon see some progress on the abandoned, neglected motorcycle.

Starting with the coolant leak from under the engine, I have determined the water pump or the O-rings on the pipes connecting to the pump were the culprit. Seeing as the pump is 24 years old I sprung for a new pump on eBay. I imagine I could buy just the mechanical seal and rebuild the water pump but I’m getting lazy.

The coolant pipes are slightly rusty so I’ll have to clean them up and give them a shot of paint. The paint on the front down tubes is chipped from road debris so I’ll touch up those areas also.

I also bought some new silicone hoses for the pipes. These hoses live directly behind the exhaust headers and while they seemed flexible and in good condition, they are also 24 years old. A lot of stuff on the Rex is 24 years old, because the bike is 24 years old. Funny, it seems like a new model to me. I can remember buying it only a few years old not a long time ago. Is this how aging works? Does time compress making distant events seem close?

The ZRX1100 comes standard with a ground skimming, low-slung exhaust system. The header pipe collector joins under the engine making my motorcycle lift too tall to fit between the pipe and the ground. Even if the jack fit under the bike you’d have to make some spacer blocks to prevent the pipe from hitting the lift. I went with jack stands on both front frame rails and one stand on a cross pipe behind the engine. With this tripod set up the bike feels pretty stable.

Once jacked up I could remove both wheels for new tires. I also removed the clutch slave cylinder that is leaking and then could access the leaking water pump.

The calipers on the front brakes are stuck.  My caliper rebuild kits came in the mail so I’ll have plenty of piston swapping to keep me busy. This is one of the chores I dread.

The chain is pretty much worn out. The rollers are loose on the pins and the thing has 25,000 miles on it.  Kawasaki used an endless type chain so I cut it off with a 4-inch abrasive cutting wheel. The rear sprocket looks unworn, which I find amazing, and the front sprocket has just the slightest bit of hooking. Most aftermarket junk won’t last as long as an old, used Kawasaki sprocket. I’ll get a new front sprocket and chain for the bike.

My initial goal with the Kawasaki is to fix the brakes, fork seals and tires. That will upgrade the ZRX to roller status, then I’ll be able to push it outside the shed for a much-needed bath. There is a long way to go to undo the damage 9 years of storage has done to this motorcycle so don’t get ants in your pants. Part 3 to follow, unless I skip to Part 5.

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Here’s Part 1 of the ZRX Resurrection!

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