Front and Rear Suspension

    Rear Suspension, i ordered a set of nice KZ 750 units, in very good condition, or so eBay man says. And the pictures of them reinforce his statement. So $32.00 including delivery, they were swiftly ordered. Pictured here:

     So I hope they look as good when they arrive. I did consider new parts and even some from china, but I am on a budget and these will keep the look pure and in keeping with the original ethos of the 59 club.

     As for the front forks, here are a few tips:

1.     Loosen the top fork bolt - in my case a 1/2" square recessed bolt, whilst still on the bike, or at the very lease, keep the forks in the yokes.

2.     Use either a impact wrench (air) to loosen the top bolts, or as i did, a breaker bar, I prefer to use a little torque as opposed to impact wrenches on occasion.. My suspension, I suspect has not been opened or serviced since 1979!

 


3.     I ordered the wrong tool to get the damper out of the fork legs. It was from eBay, my bad. The correct tool is part number 57001-142 - and is quite the elusive little f****r to find. A back up is a tapered dowel, here is hoping that works.

     The front forks, as I mentioned, look like they have never been apart, the oil, what little remained was very thick, smelt terrible and was the darkest green/black i have seen. From both forks, less that 2 fluid ounces drained!  So now, I need to improvise the front 57001-142 tool, or as a last, and hateful resort, take the legs to a shop for them to loosen and remove the hex not in the bottom of the forks for me. I say hateful, only because i want to do as much as i can myself.

     Once done, I can clean and service the forks and reassemble. Put new seals and covers on, but not before I put 20w oil into them. I chose 20w as I am a 225 lbs rider, so i wanted to stiffen the front a little. My only dilemma is whether I should change out the springs for progressive units. Around $100.00 or so.

     The lower fork legs will get a polish prior to reassembly, just to complete the overhaul.

     Update: Think I need the special Kawasaki tool, my last chance is an impact wrench and tapered dowel to hold the internals of the forks. If this fails, a large bag of f***s will be needed. Plan B being to polish the lowers forks on the tubes and then re-assemble. Assembly after replacing the seals, this is possible with the tubes still in place, but a whole lot easier disassembled. I will need that bag again....

     Update 2: I have put my bag of f***s away. With the appropriate use of an air impact wrench and a shaped wooden dowel I have got my suspension apart. Basically, tap the dowel into the damper, inside the tube and hold it, then - with an 8mm hex attachment for the impact wrench, undo the bottom bolt. Took all of 3 minutes. Job done, all stripped, ready for the service, polish and reassembly:

     The shaped dowel can be seen at the bottom of the picture. The Hex nut at the top right, damper is the short piece in the middle of the pic. I don't think this suspension has been apart or serviced in 30+ years.

The Frame Part 2

     Well, the frame has had its last cut and welding done! I am a happy man, the frame has lost no rigidity and is now 5 lbs or so lighter and looks a lot better.:

     As you can see i have removed the rear foot rests and from the 3 lower pictures, i have welded closed the frame remodeling. Giving the evolution shown below:

  

     The whole rear end is now definitely how i want it to look. While doing this i realized that the head bearings were the very old loose ball bearing type, i will be replacing these with the modern tapered bearings, around $35.00 from any store or eBay.  In order to do so i had to remove the old bearing seats. This is easily done with a hammer, long screw-driver and some percussion adjusting. It takes around 5 minutes to remove the old seating:

 

     So now to order the new bearings, to fit after the powder coating. The powder coating is going to be done by Powder Tech Plus Inc. These guys come highly recommended and are charging around $220.00 for frame, swing arm and side stand. I elected to use HVT wheel pain for the wheels and steering head stuff.     Well, today (29 Jan 19) is a good day. Took the frame to Powder Tech Plus, got a good rate for the work. It will be a week before i see the results, but have elected to go with a gloss black finish, can't wait to get it back. Also ordered new, well new for me rear shocks from eBay. I elected not to get some Chinese air filled parts, or even new progressives. The only upgrade i went for is putting 1978 KZ750 parts on order. Advertised as in VGC, and only $32.00 delivered. Pictured below from the add:

     Look good, i hope the picture doesn't do them justice! Also got fork Oil for the front.     Update: The rear KZ750 units arrived, and are better than expected, I am a pleased and satisfied builder today.


 

The Wheels

Well, i know, it has been a while. I bet you all thought i gave up! Well i had a couple of family issues to deal with and a lot of work to catch up on, but i am back.

This bike was the first in the line to be supplied with alloy wheels. Not strictly Cafe Racer i know, but in the tradition of restore not replace where i can to achieve the look (not to mention keeping costs sensible). I elected to refurbish the wheels. These are 40 year old alloy wheels.........

And technology was still catching up, so they were supplied with tubed tires. Again, because of my frugal nature, I decided to get the tires off myself. Very old tires and tubes. Additionally, the rear came with, what i now know as Rim Locks, the rear had 2 of them. This meant 3 valve size holes in the rim. The tires were a challenge, after deflating - I could not break the bead - no matter what I tried, until I used a 4 inch C Clamp to squeeze the tire away from the rim, then - using a combination of a 4" angle grinder, hack saw blade and snips i cut the tire from bead to bead. Each tire took about an hour to remove:


As can bee seen, under the tire it was a little 'gunky'. This was cleaned up with some wire wool and mineral spirits. In the last picture you can see one of the 3 'valve stem' holes. This was for the Rim Lock, usually found on trail bikes...?
So i first had to fabricate 2 aluminium plugs for the rear wheel. I do intend to run tubeless tires, however if the plug proves nothing more than cosmetic, i will run the same tire with a tube. It wont remain V rated, but this is a KZ650 not an issue. The holes were the perfect size for SAE 3/8 fine thread, that's 24 tpi. So i tapped the holes and then produced 2 threaded rivets. Tested for fit and then screwed them in place, from the inside, with a liberal amount of Gorilla Weld. Cut the excess from the outside of the wheel, filed and finished each one. The aim being an invisible fix once i have painted the wheels.

Now to the raw alloy on the spokes and rim. I cleaned and then started wet / dry paper sanding down in grits - 220 / 500 / 600 / 1000 / 1200, finishing with a wire wool wash with mineral spirits to prep the wheel for paining. To get a wheel stripped, washed, sanded and prepped for paint took around 5 hours, so that's 10 around hours in all. Below is the before and after pics, with a side by side picture of the rear wheel prepared and the front not started. The pictures do not do enough justice, but once painted they will gleam.

     Update: The wheels are done, brake disks cleaned, just some husbandry to complete on teh bolts and drive to assemble. Came out not to shabby as it goes. Not bad for a lot of elbow grease and 2 rattle cans of paint and lacquer.

 

Cutting the frame and fitting the seat unit.

     Posting today after a long while. Have had a few things going on, so my bike has taken the hit. Now settled at my new home.
     I removed the handle bares and steering from the frame. The bearings are worn and will need replacing, it was very notchy.
     The seat unit decision took a lot of time and thought, Possibly too much thinking, sometimes with a PBR in hand. Eventually, after much web browsing, i settled with Dime City Cycles, and browsed the selection. I settled on the THRUXTON Fibre Glass seat pan and the all in one PAD that goes with it. It is the right length and width, but the frame will need a trim.....out with the angle grinder.
     Measuring 6 times, i cut only 4, below are the pictures for the before and after of the trimming. As you can see from the marked before photo, there was about 3lbs of metal to trim:

The resulting cuts and a little grinding left these parts in a zip-lock, just in case... The rubber bushing may be used to support / cushion the seat unit.

     So, the frame is cut:

  

     It took about an hour of cutting and shaping to get the fit, but as you can see, not too bad. My only bug bear is the seat sitting a little too high on the frame. If i want it lower there are a couple more square lugs to cut off, the problem being is that:

     If I lower the seat unit any more i will loos the lines between unit and tank, however, it will cover a little more of the frame. I think the line is more important, but will mull it over. You can see the initial results below:

     The seat pan fits nicely, the pad is about an inch short, but i intend to have it upholstered in leather with a diamond pattern in the stitching, will use this opportunity to lengthen the pad a little to fit it a plush fit.

     So, that's it for today, juices have been flowed and interest reignited for my project. Now to look at the foot pg requirements, a little frame trimming and dressing before the powder coating. Gloss black is the decision. 

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......

     

Refurbished binnacle and more of the Home Depot DIY parts off.

     The sun is shinning and i thought to steal a couple of hours on the bike this afternoon.

     The new  refurbished binnacle looks good, sprayed in metallic gunmetal paint., glass and all electrical contacts have been cleaned. As you can see in the pictures, it is a lot better than it was, if it doesn't look the part on the finished bike then i will procure something retro from the old interweb.

     Thus, today i decided to remove the rear brake system, pedals and the wiring loom. The loom worries me a little as i am not sure whether i am going to update the ignition or keep it old skool (and temperamental / unreliable). That said the minimalist electrics and kick start does appeal to me. More reading is needed and a decision is to be made.

     Not only did the loom come off, and all an-sundry, i removed the carbs. The rubbers were perished to the other side of pre-history and  they look like shite, think a complete strip and clean is totally needed. Oh well, may have to buy a ultra sonic cleaner.

    My gorgeous and very understanding wife bought me a set of cafe bars and mirrors for Xmas, the bars look a treat, as you can see. Am loving my project, just the lump to remove. Then the front and rear wheels and suspension. After that the really fun stuff starts. The powder coating and slow reconstitution of a cafe racer.

     The engine and carb strip and assembly is going to be revealing and a challenge, although the electrics are the part that scare me, I hate motorcycle electrics.