Hello Everyone Newbie here.

[Steves]

Hello Voyager World

Picked up a Zg1200 that has been sitting for years. Figure I would save it. I been reading the forums here . Big help theres a lot of good info. This is my first touring bike. I took a test ride and I love the bike. Still working on her and any tips would be very welcome.

So far in the last few weeks I
took most of the bike apart and cleaned everything. Took each bolt out one at a time and cleaned off any surface rust. Wheeled all the plastics out with compound, swirl remover and wax. Wow she came up super.

Replaced the factory fuel pump with one from a Kawasaki mule. Shuts down at 2-3 psi works like a charm and was only 23 bucks.

Replaced the alternator

replaced the choke cable

Removed the fuel tank and flushed it out with Beyer concrete etcher. Tank looks brand spankin new inside. Had lots of surface rust.

Removed carbs and cleaned then out. Removed the mixture screw covers and set all butterflies even with a gauge pin.

Changed all fluids and over filled the oil after reading this site. I added 4 qts oil

Took her for a test ride. Everything works. Rear caliper is sticking and clutch slips a little. So I ordered all 3 caliper seal kits and new clutch plates.

Hope to be on the road soon and I think I saved another VII.

[chicagorandy]

Welcome and CONGRATS on the save. It is great to keep them on the road where they belong.

[Scott-(Altoona, PA)]

WELCOME Steves, I see in your info that you got an '01. That's great!
Also I see you are in Jersey, we have a member in Williamstown who goes by "ekap1200" on the forum, his name is Gene and I believe you and he are fairly close. You should look him up, connect with him and he can give you some input on these bikes as he's done quite a bit to his.
Not to mention that he makes some farkles for them as well!

Keep us updated on your progress and when you have time post a few pics, we all love pictures!
Again Welcome!

[Steves]

Thank You and post pictures this weekend once I get the bike back together.

[cushman eagle]

Welcome aboard a great forum and a friendly,helpful,family. It sounds like you have already started learning about servicing this great motorcycle.You already know this is a place to ask about your bike,and to help others.

[Mr Jensee]

I hope you addressed the oil overfill.

[Gator Mike]

Welcome aboard. Sounds like you are on the way to making a great machine. Carl Leo is the guy you need to keep in mind for the technical stuff. He was with Kawasaki for more years than many of us have been riding. In regards to your clutch you might want to give him a shout as there are some words of wisdom about thicknesses of individual bike clutch plates that he will help you with. His comment to me when I spoke with him was that clutches discs usually aren't the problem. Certain years have a star spring affair that break and can cause the clutch to slip. Might be worth your time to give him a call. Good luck with the bike. It's the best kept secret around............Gator Mike

[Steves]

Question for you guys. I dont think I have any issues but. I had the bike running today. Is there any normal bottom end noise on these engines. If you listen real hard you can hear some lower end noise at very low rpms. But like I said you really have to listen for it. You cant hear anything riding just if you lean over and listen real hard just off idle. Buzzing the throttle and its smooth and quiet.

[Mart656]

Welcome aboard!!! My friend got a 1200 last year and hears that same noise you are describing, but so far no issues to speak of and he drives it daily. I've had my 1200 for almost 3 years and still love it.

[jre258 in SoDak]

The noise at idle might be coming from the balancer shafts. The backlash might need to be tweaked.
Jim

[Steves]

The noise at idle might be coming from the balancer shafts. The backlash might need to be tweaked.
Jim

Jim

Thanks That is my thought. Most people would of never noticed but being a auto/Diesel tech for 30 years just cant help but to pick things apart.

Thanks the rest of you for the warm welcome.

[kjsett]

Just sayin that if you come to Estes Park, or some other AVA gathering, you will get all sorts of free advice on anywhere from: "don't hear nothin" (too many years on other loud bikes), to, "oh my God, you got here with that goin on.........."

My bike has all sorts of noises, just usually chock it up to.. "thats just the way it sounds". Course I did have one that was more feeling in the pegs than sound. It turned out to be the u-joint at 40k was coming apart. But she never left me sitting by the road (once at McDonalds an hour from home, but that wasn't her fault).

Enjoy your best touring bike in the world (at least for the $),
Ken

[ekap1200]

I met Steve today, I had a kdx200 running in the driveway and didn't even hear him pull up. Bike looks in great shape for a 500 dollar deal. We talked shop for a while as I looked it over and the only issue I seen was the sacked out front springs. She's a keeper , great job at getting her back to running condition. If it had new front springs I would take it out to the rally no questions asked......We will be seeing more of this bike for sure and each time it will be looking and running better....
Any one that has a spare radio cover , keep Steve in mind, he needs one. Gene Kap.

[Scott-(Altoona, PA)]

Well Steve, I see that you got together with Gene. I'm assuming that your meeting went well and hope that you left with a more comfortable feeling both about the purchase of this wonderful machine and about the AVA.
I hope he also mentioned the local chapter of the AVA, the Mid-Atlantic Voyagers. You are more than welcome to join in on any gathering and provide opinions and input. We are an open minded/like minded group of folks who don't care what you ride, but that you ride. A few weeks back 4 of us met up for a charity ride, last fall 13 of us spent the weekend having a blast riding through autumn colors in the mountains of northern PA.
Heck that weekend my bike was out of commission so my wife and I took our car and rode tail taking pics!
Welcome again, hope to meet you down the road! Stay safe and ride smart!

[vxiirider]

Steve I have a set of OEM springs out of an '03 that have only 12,000 miles on them, they are yours for the cost of shipping.

John Ramsay

[Steves]

You guys are awesome. Gene is was great meeting you yesterday. BTW Genes shop is amazing and organized.

I replaced the clutch friday night and that fixed the slipping. I also adjusted the balancing shafts and she really purrs now. Took it out and shifted at 7500 and she rips pretty good for a heavy bike. All thats left is the front springs and fork oil also as Gene pointed out to me I need a radio cover.

John thank you so much for the spring offer you have a pm.

[chevyman1]

Steves
I have a set of front forks with Progressive springs in ready to install.
If you are interested let me know.

[sir old dirt]

Steve,
You have been a busy bugger.
Congrats on a super find!
Hope you make it to Estes Park