Zephyr 1100 Maintenance and Repair

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The handlebars have arrived, so let’s finish up the remaining work.

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The tank has gotten dented. Replacing it is more efficient than fixing it.
Replacing fairings is something I’m not very good at. It requires a lot of masking and careful attention.

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I’m installing genuine Suzuki metal-lined trim. It’s effective for paint cracks and chips at the edges, and it also helps cover things up, so it’s really great.

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The fuel petcock is extremely dirty. It doesn’t look like it will come clean at all, and I wouldn’t install it as-is on my own bike, so I’m polishing it with that mindset.

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After assembly, it looks really nice. We can polish parts about the size of the bottom case or stem, so if you’d like something cleaned up, please feel free to ask or discuss it with us.

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The Two Brothers handlebars have finally arrived. They came as a set, so I replaced both left and right.

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The oil sight glass is pitch black. I’ve replaced it with Newtech NC50 10W-50.
The battery is looking a bit questionable in this cold, so it’s currently charging.

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