Kawasaki GTO 125, Time to Time Small Repairs/Cleaning

[waqasjamil]

Nadeem Sb did a Marvelous Job... No Doubt in that..
I restored My GTO after watching his reference posts and got much help from the pages of manual which nadeem bhai shared... Thanks again.

One Request again is to Scan a Complete Manual Book of GTO and Upload as PDF so that the precious document can be preserved.

[burhanzaki]

Brother ib me ur number i will guide you jitna mera experience hy sleeve sy

[basic]

You are welcome.
At the moment I am quite busy, will try my best to up load pdf.
In the meantime you can get required information from this thread.
Regards.

[pwuser162753998561]

I’m so glad to find your kind reply!!! . I haven’t checked the forum in months and today I came back to see some of your pictures as reference and Voila! You had replied to me. Thanks, mate, it’s an honor . I fix the key drum with your detailed information. I’m replacing some things like the muffler gasket and o ringer, plus the regulator and probably the rectifier. It’s interesting because it has both a rectifier and regulator separated. About your question referring to the size of the piston, it is still the standard size.
I found some super interesting information about all the different GTOs. Displacement, power etc etc. Mine seems to be part of the GTO “génesis”

[pwuser162753998561]

[pwuser162753998561]

You are so kind by sharing your number, I do have a few questions. My GTO has a regulator and a rectificator separated. I’ve seen some GTOs with only a regulator that acts as both a rectifier and regulator. Well, as I was saying, mine has two components. I remember that I had problems with my batteries due to the fact that they boiled because of an overcharge probably. I’m no electricity expert but I’ve read that when the regulator is faulty the symptom is overcharged batteries. So I decided to e place the regulator but I’ve found the only available regulator now is both a regulator and a rectifier. So, I need to replace my two components for only one. But I will have for wires to connect (pink-white-blue&white-yellow) in a new module that only has two connections! . I am adding some pictures to clarify….

[basic]

Also much delighted to see you here as a passionate GTO lover.
Nice sharing different machines ️.
Your machine is one of the best.
Best wishes.

[basic]

In my case two pin connector for rectifier and three pin for regulator.
Check your wiring diagram and follow accordingly.
IMO you should not change the originality.
Have to change regulator once, which I found at some old parts market many years ago.

[basic]

You can also find both parts in this post.

Some 6 volt electrical parts. some wiring etc. [image] [image] [image] [image] [image] [image] [image] [image] [image] [image] [image] [image] [image] [image] [image]

[pwuser162753998561]

Yes I am trying to maintain the original parts but some of there are not available anymore such as the regulator and rectifier so I would have to replace it by the new regulator/rectifier “all in one”.
Currently I am dealing with some magneto issues and waiting a few parts for the muffler.

[capsat]

@vickytulla after very long there is an interesting restoration / repair thread about a 2 wheeler

[vickytulla]

this came to life after quite some time... ALways fantasized these 2T old school bikes.

for the discussion, @pablo he is from the other side of the globe but if this bike was sold there in his country I am sure he can do little trrophy hunting and may find donner bike parts from scrap yards.

[basic]

In 1979 G7T have only rectifier for charging/regulation, which was ok I think.
Best of luck with the restoration.

[pwuser162753998561]

I’ve bought the rectifier/regulator “all in one”, it Should arrive soon. In the meantime I need to buy an extractor to fre the magneto wheel and “time” the ignition. For some weird reason when the ignition marks align, the piston is not even near the PMS. Now I remember that the last time The engine ran, a series of misfiring happened and that was the last attempt I did to start the engine again. I was not interested in the old GTO anymore… Now old things seem to be more valuable for me so it is time to bring my antique “friend” to life again.

BTW, this is the original 30 years old chain. I’ve cleaned it thoroughly and it looks as good as new.

[pwuser162753998561]

Update August 4, 2021. Front caliper unmount and cleaning. It was not in a bad condition, only a bit of a muddy-sticky-gummy resine inside the piston housing. The 2 orings were in a fair condition, I am buying them tomorrow.
Ive checked the main coil and the resistance is a bit out of the tolerances indicated in the manual that you @NadeemNabi have kindly posted.. The reading of the primary widing is 1.7 Ohms and it should be between 0.4 and 1.2 ohms. I will check the status with the motor running and replace the coil if needed. Do you think 0.5 ohms out of the tolerance is too much?
Ive mounted the headlight and turn lights (front left is a bit misaligned, I know).
I found the front fender to be a bit crooked, seem to have a bulge in each side, I should correct it with extreme care but the only method that comes to mi mind is a hammer. Any ideas?
Last, the saddle is in a decent condition except for two cuts that make me think if I should fix it before mounting it again and extend the damage with the daily use. What do you think?. Im just worried that the "saddle shop" could ruin the nice and tight fitting of the skin. What would you friends do?

[basic]

Good going
Coil resistance should be maintained as described in the manual.
Performance and smooth running depends on proper electronic system.
Fender dent can be fixed with the help of bench vice. Vice jaws should be wraped in heavy cloth to avoide any marks.
A good Saddle shop can fix these faults/cracks easily.
Best of luck

[khan.rafiullah77]

Sir, how we can identify japan made and pak or china made engine cylinder OR in other words what is the difference btw both japani cylinder and china or pak???

waiting for your valuable reply Sir.
Thanks

[pwuser162753998561]

Mine says “made in Japan” on the side of the magneto wheel.

[pwuser162753998561]

Dear Nadeem, as you predicted Vice jaws fix the dents of the front fender, now is aligned again.
Front caliper is serviced and works perfect, as a note of color the piston packing rubber is the same of the Opel/Chevrolet Zafira, I saved a few bucks because the same oring in a motorcycle store costs 4times more.
I have an electrical issue, weak spark, hence I’m replacing ignition coil, lights coils, breaker and condenser. I’m taking no chances trying to find electric bugs that drive me crazy.
I also found that when testing the turn lights one side works with half the intensity of the other, it’s weird. I still don’t have the new battery so maybe it’s a matter of low power but I wonder why only one side shows the lack of intensity in the lights.
Hope you enjoy my humble restoration. See U!
PD. Following there is a short video of how I’m testing both the coils, I think they are broken. What do you think? Coil Testing

[pwuser162753998561]

Back in 1979 magazines said about these Kawas…