Updated 2026-07-15
My enthusiasm for finishing my C2 model has not diminished from my efforts in June, (See: https://sidyoung.com/zx9-r-june-progress-report/ ) and I now have a number of items from the crash completed as well as some long over due maintenance tasks completed.
One of the key tasks was to rebuild the Brake Calipers with new seals. So I stripped them down, initially cleaned them on the bench and then washed them in hot water and laundry washing liquid in the kitchen sink. The old seals appeared to be very thin and flexible and the pistons were very tight when pushed in and pulled out. A quick read of the service manual actually shows an entry reporting that they should be done every four years which took me by surprise!
During the re-assembly I fitted new seals, and the cleaned up pistons went in a bit smoother.
The next item to finish off was the forks, I cleaned them, stripped them apart and fitted new seals with new 5W oil. The hard chrome is in excellent shape and there were no issues removing the 8MM set screw from the base and pulling the forks apart. The oil as expected was rancid.
Finished Tasks
I have been able to tick off a few more jobs, these include:
- Refitting the stator cover
- Fitted a new Clutch Return Spring
- Installed the battery and statically checked the electrical system.
- Lubricated the steering head and adjusting it for smooth operaton
- Fitting a new clutch cable after lubricating it with 5W oil.
- Lubricated the throttle cables.
- Completed the assembly of the switch gear.
- Drained engine oil, replaced filter and refilled clean oil.
- Fitted new clutch cable (and lubricated it).
The remaining task on the engine now is to clean up the carburetor fuel bowls.
While replacing the Clutch Return Spring I discovered the clutch cable was about to fail, less than half the cable is intact. So I will order a new one today (now done and fitted).
UPDATE: Cable was in stock at Teammoto Kawasaki, so I was able to pick it up and fit it that evening (after lubricating it with some 5W fork oil).
Directional Wheels
Here is some trivia for you, the C2 wheel rims are directional, as are my Dunlop tyres!
The only reason I can think of is to ensure the spacers go in the right side? But it’s something I will follow up on when I get the tyres refitted (after the rims are painted).
TODO List for July-August
- Take back wheel off, clean it up, remove the disk.
- Take the wheel rims in to get the tyres off, then take the tank, rims and the new front guard (fender) into the painters.
- Buy the new “Wave” disks (they are made by Arashi in Japan) as well as a HEL brake line kit ( decided red lines might be the go).
- Assemble complete Front brake system on the bench and bleed it, ready to assemble back onto the frame.
- DONE – Clean up the corrosion on the stator cable connector.
- Mount the rear bodywork.
- Start the engine 🙂
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