The tear down is complete!

     So today is a good day, I took the opportunity to steal a few hours this afternoon to complete the removal of the front and rear end of the bike. As with all other parts on the kwaka, it was relatively easy, once a liberal amount of WD40 and elbow grease was applied to the rusting bolts, including the now expected home depot specials.

     

The tools required today were;

          1. Ratchet Wrench

          2. 13mm, 14mm, 17mm, 24mm and 27mm sockets and wrenches

          3. WD 40

          4. Soft Faced mallet

          5. Bike stand - this is an unexpected quality item from Harbor Freight.

     The work began:

As can be seen, the cush dive rubbers are in new condition, ans is the rear sprocket and there was new grease in there, I think a sprocket may have been changed. I think i will just give the wheels a clean and see what state they are in. The quality Chinese tyres will, unfortunately, have to go. The rear caliper will need an overhaul, same as the front got.

     To my delight, the front and rear discs are not only identical, but are like new, hardly worn at all.

     The most problematical part of this phase was the removal of the rear spindle, it was very very secure, and required a little percussion adjustment. Not thinking i applied the required force with a steel faced hammer and no soft plat, thus i did mushroom the spindle end a little, it is not, in any way un-serviceable, but will require a little love.

Not much work required here, as i have said, i will clean the wheels and see what state they are in before deciding whether to gt them powder coated along with the rest of the frame.

I have decided, at the time of typing that my colours will be black and red, with gun-metal accents.

The tank is going to get indents, I am yet to decide upon using body work curved hammer to indent, or cut and weld the tank, I am leaning towards the former.

     After the wheels came out, the suspension proved refreshingly easy, 4 bolts at the front and four at the rear was all that was required and out the twin shocks came, as did the forks.  ]The fork lowers will need painting / coating in black or gun-metal. The rear shocks are destined for teh trash. I have my eye on a Chinese rip-off of some Hagons, so i am going to invest. See what happens. The front forks are in good condition, that said, i am going to refresh the fork oil and put progressive springs in too.

     Now the expense and fun begins. The purchase of parts and the rebuild.

Engine is out!!

     Finally, after much dis-assembly, and the help from a holidaying brother-in-law, the engine is out of the frame! It was an east task, just remember to take the chain off first - find the split link, and remove it, then, the rusty chain came out. The chain just has surface rust and was surprisingly free in movement.
     For the removal you will need a 13mm, 14mm and 17mm socket and accompanying wrench. If you have a hoist the engine is tricky but can be maneuvered out of the frame, but in this case two is better than one. A little jiggling and the lump was out, weighing in at about 80lbs, including the gearbox.

                                                       

     The frame is now accessible. Front and back end off next. Plan is to buy my cafe seat and trim the frame appropriately, everything rear of the shock mounts is going, as is the rear foot peg supports. Will have to devise a simple exhaust mount, going for an up-swept look, undecided about single or twin pipes.

 

     I did invest (not sure if this is the right word for a Harbor Freight tool), in a motorcycle lift . With the 25% coupon it only cost me approximately $72.00. A bargain and it seems robust enough for hobby use. Assembly was easy and it can lift the KZ 650 with ease, it is rated to 1500lbs, but would not want to go there!
     Next, the front and rear are out and up for a refurb, cut the frame and fit the seat. Still not sure which way I am going with the electrics and battery......