Rebuilding a barn find Kawasaki GPZ900R Superbike - Part 5 

Thanks for the shout out mate… I feel very honoured. 😊😊😊 Now I can tell my wife and kids that I’m an influencer 😂

Kate is brilliant 😊 We like Kate 👍

Watching from the start of this series, just a tip, you don't need to remove the fuse to check for voltage across it, the tops of the fuses have a small exposed metal contact point that you can get the multi-meter probe onto to test. Good luck with the build, huge undertaking.

Couple of pointers. As mentioned - they are security bolts in the ign switch - you might have to drill them out. On the fuses, each side of the number are two metal contacts - allows you probe for voltage without pulling the fuse each time :). Finally, pop some strips of rag into your inlets - stop anything falling in there.

You could try cleaning the starter solenoid terminals. Looks a bit rusty down there. Also the terminal post on the starter. It that don't work you can get it cranking with the quick and dirty trick of bridging the terminals on the solenoid with a screw driver. Make sure there is no fuel around as you will get sparks.

The number plate light fits below the rear light but above the number plate, if you take your plate off you will probably see the attachment holes.

That was a nice thing you did for that lady👍. Good Karma will come your way!! BTW really enjoying your videos! Keep up the good work!

I would appreciate it if you could get a bucket of soapy water and a sponge and remove the grime from your Ninja, especially working around the frame. It'll make things easier for both you and your viewers to see what's going on. Also, your bulbs are coming back to life slowly because their contacts will be tarnished and the electrons are having to fight their way in and out. You'll get an instant improvement if you pop them all out and polish the contacts for ten seconds with fine wet and dry. It's satisfying. Give it a go ... 👍

Those little SV's are amazing bikes I've had two of the later models and that engine is a beast, they handle so well too

It's cool to see that you bring back to life old neglected bikes! You have 3 out of 4 main japanese brands. Maybe a birthyear Honda for Kate next?

The ignition switch is held on with "Shear Bolts" and the hex you see is the remains of the head that shears off when tightened to a specific torque. Its called a "Starter Solenoid" between the battery and the starter motor.

It's nice to see your making progress. Also good to see I'm not the only one that likes messing about with old bikes. I don't think I could film me doing it tho I swear and curse to much and question what the hell am I doing this for but I carry on anyway the satisfaction of solving a problem is worth it.

This is so entertaining. Thanks! 😊

Really enjoyed that episode...every day is a school day..I have never understood wiring diagrams...keep it up Ash...loving this !

The mighty thundercat! Have one too at about 65k kilometers and its still starting everytime no issues. In my opinion its an often forgotten bike cuz its always overshadowed by the r6. But the cat sits more comfortable and doesnt have that much less power. Keep an eye on the fuel systems and that thing will run forever.

This is great stuff, I can’t believe you are attempting this on your drive, however you do seem to be making progress and I am intrigued on how it’s all going to pan out. Thoroughly enjoying every episode and subscribed. Well done for helping the lady out.

Really enjoying following your progress. Way back when I was s young pup I owned a GPZ900R. Awesome bikes from the days when bikes could be super quick without been super uncomfortable.

Nice one @AR. Keep plugging away !

Coming along nicely

Thanks so much for the mention Ash. Another good episode - Keep em coming.👋

Yeah! Another episode

Excellent ,your work is paying of

How nice are you, it’s fair to say most people going home would just indicate and pass the broken down car, you’ve definitely topped your pos Karma up, every time you focus on those Gpz clocks I get nostalgic for mine, I’m enjoying this series so much thanks…. p.s We need more Kate on the channel, I think you might be the luckiest man alive, she is right tho, the SV is a great bike 😎

Great series

The solenoid just needs terminals cleaning and Vaseline putting on connections

I think you would do well to dissemble both the ignition switch and the starter solenoid. On your bike, you have an ignition relay for all things sparky and the starter solenoid (which is just a heavy duty relay) for switching power to the starter motor. I've had trouble with both these before. After seeing your truly excellent work on the fuse box, I'm certain this is within your capabilities. And it will make interesting viewing. The ignition switch is straight forward but assess the guage of the wires that go in and out of it. and decide whether or not they are heavy enough for the full electric load the bike will post through them. I was shocked how thin they were for one of the bikes I own and so replaced with higher rated. The solenoid is trickier because you will have to desolder the thin trigger wires to lift the cap clear. Do this very slowly and note the routing of those thin wires inside the body as you lift the cap. You will find corrosion on the thick copper contacts but can flip them over if heavily pitted. Or do the boring/sensible thing and buy a new one 😄

That’s cool that your volt meter is on your speedometer. Wish mine had that

Steady progress

You need to find out how to prime the fuel pump on your Thundercat, there are two ways on the old Kawasaki's, one is the easiest and my preferred way, and that is to just holding the clutch lever out around an inch and pressing the starter, you will then hear the pump prime, takes a few goes to get it first time, but turning the engine over brings the oil pressure up which helps also. The other way is with it in gear and the side stand down, and press the starter to do the same. You really shouldn't need to adjust the idle screw, the choke richens the mixture to help the cold start, but it struggles as there is not a lot of fuel left in the system after sitting. I like to run the carbs for as bit with the petcock off so there is less fuel in the system while not being used as it gives the rubber seals etc a longer life.

Well done ,your hard work is paying off 🙂🙂

It’s called a starter solenoid the part that’s faulty before the starter 👍

Good new logo, good on that chap. Good on yourself for the good deed, and good to see the bikes you were hiding. So, what i mean to say is...good. arf. 😀

The backside of the fuses are open for measuring. You do not have to remove the fuse. Cheers from Germany

Well done Ash doing a nice job on the bike , but must admit the wife’s bike is better and looks better than the thundercat 😊

Love this - really great to see how, as the subscribers rise, then the opportunities rise too - fantastic to see, M8 - long may it continue! 😁 Oh, and real kudos for stopping and changing the lovely lady's wheel for her - It remains to be seen whether you'd have stopped for a middle aged, fat Irish bloke with glasses🤣

If you like the Thundercat try a Fazer I have an FZ6 Fazer and absolutely love it

Only one wire goes to one side of the clamp

My OCD is screaming that you didn't wash it before you started all this ;)

That Thundercat is a cool machine. I would say the starting problem is a vacuum leak due to old rubber hoses. Have you got any starting fluid. Best and easiest way to check for a vacuum leak.

Awesome job, wish my wife would ride with me but she despises motorcycles haha.

A lot of jump leads only have a connection on one jaw. Hence if you clamp partly on the terminal and partly on the battery casing (as you had) you might land up with the wired jaw on the plastic casing and no power. That starter solenoid is a fairly basic one. A trigger wire, and earth wire and the 2 main cables, and common to loads of bikes. You should be able to easily find one. For the Thundercat, might be worth checking the valve clearances.

Best thing I ever did to my gpz900 was to fit a gtr1000 front wheel, makes them a lot less twitchy.

Theres not many people out there that would help out other people .

Been watching couple ur videos. I sub scribed only got one question. Why is the horn so important. I been laughing watching. I know he going back after the horn. Why horn matter it’s just positive and make ur own ground lol. Ur fun though bro good videos. The horn thing is too funny.

Tiny Tim has come such a long way! Just do the voice once, whilst working on the bike 😆 🤣 😂

Basicly any 12 v motorcycle starter relay will work.

I hope your security's good after airing bikes on YT, that and FB exposure notorious.

Ash when you find the paint code for silver and blue please post them because I need the also cheers

It’s called lithium grease it’s for electric stuff

I'm watching this video and saying to myself ffs spray some electrical spray into the ignition ffs

Take out plugs then try starter ?.

😃

Get a decent pair of jump leads first.

Whats the other bike?.