philpassingham

Hi Mike,

if you like the classic way this is the best one I can recommend:

https://www.louis.de/en/artikel/universal-auspuff-conic-long/10027110?list=157529144&filter_article_number=10027110

This is the long version I describe.
A shorter version is available as well, but the sound is not so good as with the long ones.

Affordable price,…[Read more]

What I have used to get the bearing shell out ? Heat, hammer and screwdriver.
The poor frame !

Have to clean the harms and major scratches (that I have caused during this action) out of the seat in the frame, where the bearing shell sits.
Then use the correct glue to install it again.

At least it is removed !

Well, moved on this weekend.
Fitted the baggage carrier, rear blinker to it, found that the larger Krauser cases doesn’t match, are locked and I don’t have a key. So I will go with the smaller ones.
Front crashbar mounting optimised and fitted a rear left crash bar as well. This is ideal to move the bike onto center stand. Can’t fit the rear right…[Read more]

Hi Hans,

it is the recommended tool after the other one is obsolete and should work.

To handle that tool it is important that the engine is complete. You can’t use it with the cylinderhead lying separately on the work bench.

How to use it ?
First measure the valve clearance and note down the number 😉
Ensure the small cut-out in the valve…[Read more]

Hi Andy,

ok, it starts in german.
Wait a few seconds to get the full page loaded and click on this video, which is in english language:

No specific link available.

Cheers and double face-palm,
Michael

Hi Marko,

I would go for a 4-cylinder engine !
750Fours are a shame, go for 1000ccm at least.
Different ride, but powerful and long lasting even with “hard” riding.
A very popular bike at reasonable low price in Germany is the Suzuki Bandit 1200. Half fairing and ABS on board.
Kawa ZXR 1100/1200 are great but far more expensive than the…[Read more]

Hi Phil,

you are correct.
Spooky quiet.

Cheers, Michael

Hi Phil,

you are correct.
Spooky quiet.

Cheers, Michael

Hi Kaye,

good work !
I love the idea to reuse the leather of a couch 😉
Have fun !

Cheers, Michael

Hi AtLarge,

thank you !

Will work on this weekend.
Have to invest in a set of new tires.
Sure these will be Bridgestone BT45.

Cheers, Michael

So what was the reason for the black spark plug and that the engine was not reving more than 3.000 rpm ?

After checking the camshaft timing I fittet the camshaft drive tensioner correctly and made a compression test.
Result is the same for both sides and very satisfying.

Ok, only the carbs are left.
Well, hmmm, my fault !
I haven’t fixed the…[Read more]

more pics:

– old ignition cables
I have removed the outer cover of the cables to reuse them on the new cables.
Bent one of the old and extreme stiff cables and the isolation just cracked

– removed the cam chain tensioner

some more pics in random order:

Still the old drive chain kit

Just to post some comments and pics of the progress.

I rode the bike for approx 4 km / 2.5 miles on the small road in our village.

Yes, it lives again 😉

Starts fine, idles fine but will not rev more than approx. 3.000 rpm !

Checked some things after the test ride and got a shock as I found the timing chain was not tensioned and the tensioner…[Read more]

Hi Stuart,

I can understand your situation.
To bad that you have sold the Kawasaki.

You may contact the buyer again and give him a hint, that this forum exists and he is more than welcome to join.

All the best to you and have fun riding your bike 😉

Cheers, Michael (from Germany)

Hi AtLarge,

thanX !

It gives me some inspiration where to go with my over-next project, a scrambler twin based on a LTD 😉

Beside my “Lofoti” the next project will be a Caferacer based on a B3. Clip-Ons, dual disc brake in the front, 2-in-2-exhaust, all that already here. Preparing the recessed foot pegs in the moment.

I love the Storz rear…[Read more]

Wow, Lonesome !

I have never seen this prototype.
ThanX for sharing.

Cheers, Michael

To grind the openings in the frame I have used this sanding band stuff:
http://www.dremeleurope.com/gb/en/sandingbands-6060-ocs-c/;jsessionid=4A74BF1D0B7DAD9CC52D96BA4534A158.sl172-vm_1

13 mm, #60 and finally #120

Be aware that these grinders try to run over the surface (some force in rotation direction) and initial positioning is difficult…[Read more]

Oh, missed to post a pic of the ordered spare parts:

e.g. steering bearings, starter clutch repair kit, fork sealing rings, etc.

Of course I have used these parts when working on the bike 😉

more pics:

You can see that I have ground “openings” into the frame. Reason is the possibility to remove the outer bearing ring of the (Kegelrollenlager) replacement steering bearing set.

New steel flex tubes with black fittings and clear coating mounted. Fixed the new hand brake lever over night and today I have a clear brake pressure point 😉