Saving a '81 KZ750-E

calum wrote: OK, probably the original tank then
I have an OEM o-ring lying around if you want me to measure it. It isn't shaped like the petcock ring so you can just grab a nitrile o-ring out of the box.

Knowing the cross section diameter and the major OD would be really helpful. If the sensor doesn't work, it would be easier than making my own block off plate and sealing that up. I will do the math using the groove OD for comparison. The o-ring OD should be a touch smaller than the groove OD.

The sticker on the frame head actually reads JKAKZDE 19 BA ...
I checked CMS again and saw that although I was in the E2 section the parts diagram for the tank was from the E1. Here's the page for the E2 tank - it just doesn't have a diagram:
www.cmsnl.com/kawasaki-kz750e2-1981-usa-...15.html#.XoxFa25uLic

The part numbers for the fuel sensor are actually different to the H1:
www.cmsnl.com/kawasaki-kz750h1-1980-usa-...37.html#.XoxGY25uLic

EDIT: The o-ring for the E2 fuel sensor is 430581004 (same as for the H1) - I'll post the dimensions later today.

Impressed myself today by remembering to measure the o-ring
Cross-sectional diameter: 2.1mm (probably just 2mm)
Major diameter is about 36mm (the callipers in the photo below read 36.1mm)

I came up with the same OD with measuring the groove. The depth is 1.75mm, and the width is 2.75mm, so I was guessing a 2.5mm cross section. The petcock parts including the screen and frame survived the parts dip. Everything cleaned up well.



With your help, I managed to track all the parts down on Partzilla. $44 shipped works for me just to plug the hole. We will have to see if the switch works when the bike gets completed.

That petcock looks a lot better! Glad you found the parts for the sensor.

Half of my POR15 chemicals showed up today, but it was the second step in the process. The cleaner/degreaser won't arrive until later next week. But on a brighter note. I also got my new mirrors today! A bit tight, and the final adjustments will need to be done when it's on the ground.

I was going through some older photos of when I first started working on this project. Just a reminder of how bad this bike had gotten before I picked it up. Hopefully the original owner (a very close friend) will be able to come for a visit after all the travel restrictions are lifted to see how much his old bike has changed since he last saw it!

The debris field from the first time blowing it off with compressed air. After all the bodywork was removed, I had this same amount come off a second time from areas the air couldn't reach.


Unfortunately the PO's maintenance, or just plain washing it once in a while, was virtually non-existent. Refinishing the engine cases is still something I am not really looking forward to.

Thanks for the pics. I'm always amazed at how some folks totally neglect even the simplest type of bike maintenance - such as even a simple cleaning. I'm glad you are saving the bike which would otherwise probably ended up being scrapped or parted out. Ed

Man that bike has come a long way! It'll be interesting to see a before and after of the motor once you get it back together.

These are from the day I picked it up. I had to take off the front wheel and get a new tire put on it just to roll it to the trailer. Surprisingly enough, the rear tire was still holding air. Twenty eight years in one spot. The front tire was gone due to sun exposure, I guess the rear was more covered and didn't suffer as much damage.


The registration tags expired in July 1991. It was kept active on a non-operation ever since.

Ouch :pinch: it hurts to see a bike in that state.

Out of interest, what did you do with the original forks? They look OK in the pictures.

The forks are on a shelf in my shop. All of the original parts are still in my shop. The forks are leaking as the rubber parts are all old and cracked. The lowers are not looking very good - the clear coat is coming off and would require refinishing. They would need a total rebuild. The entire front end is available with the exception of the lower triple clamp. I used the stock stem and pressed it into the CBR600-RR lower.