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③GPZ750F Front maintenance and other repairs

Everyday Events (Work Log)



I thought the step bar was just bent… but then I realized… seriously… no way.
But looking at it now… judging from the rust, it seems like it might have already been damaged?
The mounting boss is still firmly attached—I’m amazed, but this isn’t the time to celebrate. What should I do?
I need to go with the least troublesome approach.
I heat it and tap it to restore it to its original shape as much as possible.
I weld all the holes closed. My welding is already rough, and the position is acrobatic, so please bear with me.
It looks safe at first glance. Next…
Shearing cut → I fabricate a patch with a three-roll machine and apply it to increase confidence even more.
First I weld the patch to the frame.
Next I fabricate a step boss and install it.
The bolt on the underside was also broken, so removal is complete.
And so the restoration is complete.
Since I removed the swingarm, I cleaned and lubricated it.
Once you start noticing things on a motorcycle, you can’t stop… Rear brake clamp edition.
I’m using the clamp from a Bandit 1200 K6.
There’s plenty of meat, so I tap and open the anti-rotation hole and we’re done ×2.
With an ultra-low head, it won’t interfere with the hose, which is nice.
Just lift and insert. A little work now makes things so much easier going forward. *Are you cutting cable ties every time?
I think it’s good to keep in mind that you might also clean the caliper or remove the swingarm.

This clamp is 100 yen, but the ultra-low head one is more expensive…
After that I made a fenderless setup,
and made a tail light mounting bracket,
Rigid is basically not good. It breaks first… but the trick is that it doesn’t break again right away.
Of course, “if you don’t ride it, it won’t break” → “it doesn’t break so it must be OK” → infinite loop.
It’s a hassle every time… so I welded it again.
When I attached the fairings, the threads stripped → helicoil. There were all sorts of issues popping up…
I joined the Barling Society and all is well? Anyway, it’s complete.

That concludes this work session.
Everyday Events (Work Log)
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