if i were you mate i would strip the front brake calipers and reseal, they are **** for piston seasure and result in brakes dragging and wearing pads fast

 

I hope you can find all the screws that are laying around on the floor! hehe.

Good luck with the project!! Are you replacing steering head bearings?

 

Yep, I'm doing the steering head too. I'm trashing many of the stock bolts for new Stainless and aluminum (where appropriate).

How about the wheel bearings? What's the service life of them?

 

Wheel bearing should be checked alot on these bikes due to their weight. They do tend to have the need to be replaced more often and they are quite cheap to buy. Replace the seals too.

Are you using tapered roller bearings on the steering head? They are much much better than the ball type.

 

Never a bad idea to do the wheel bearings if you're doing a stripdown - they are relatively cheap - a full set for the CBR1KF 's available on e-Bay for about $20 for front and rear. I did mine 21/2 years ago, but am thinking of doing them again. 5 bearings total, 2 F 3 R, with the carrier bearing.

 

Bearings on the way! I'm not crazy about these brakes however. I'm used to the opposed piston type, which aren't as prone to sticking.When I picked up my Zephyr 750, I found that the SV 650 and Concours used the same fork. I found a conversion kit on the Concours forum and I enjoyed the power of 6 piston Tokico's. I wonder if our forks cross reference?

 

These are big, heavy bikes and are hard to stop at 252Kg's, but if you learn to use front and rear brakes together, you can pull them up fairly quickly. Rear brake is inclined to lock up if pushed too hard, so it's a bit of a learning process, but you get used to it.
To uprate the brakes, you may have to replace the entire front end, an expensive business........
not sure as to cross-referencing with other forks, but please let us know if you find anything....

 

I picked up a powder coater from Sears..Not too bad, eh

 

Pics

 

I had a VERY busy weekend while the board was down.

1. Replaced the headrace bearings. Hard job. Used All ***** tapered bearings.
2. Replaced front and rear wheel bearings
3. Installed forks.
4. Replaced rear swingarm and shock. Greased fittings.
5. Changed brake pads on front and rear calipers.
6. Fitted front master cylinder from a ZRX1100 along with SS front lines.
7. Replaced tires
8. Installed wheels
9. Installed new chain
10. Powdercoated chain adjuster blocks black
11. Installed refurbished pegs
12. Installed new Vance & Hines Exhaust

SHEESH..I think I'm still missing some things I did, but when I was done with this my body ached like I was 80 years old.

I still need to tighten up some bolts, etc and add fluid to the clutch and brakes. Not too bad for an amateur. So far I have refurbished, inspected and replaced every system in the bike except for the engine guts.