Kawasaki Trail KE 175 restoration from dead to alive

[mbaqurashi]

Well, I bought a KE175 from Mr. Asif (PW: justtrust). It was in about a squillion pieces, but apparently it was all there! As per Seller, only its fuel tank & its silencer was missing. But, later I realized that is Crab & left side cover was also missing.

Fining these missing pieces were thought as great deal of tension, but by grace of Allah I found all missing pieces easily with help of fellow beings.

We were able to complete this project in 5 months. Me and my co-mate my brother Ishaq had started working on it in Aug 14 and finalized it on 6th Jan 15.

[Shafin619]

Trail bike is love :* How is the power compared to Yamaha DT175? I am a big fan of dirt bikes

[mbaqurashi]

initially we strip is down to frame. Removed engine and wiring. Remove rust and paint by hand with emery cloth and re-painted it to black.

[mbaqurashi]

Yar I saw Yamaha DT couple of time but couldn't get experience to ride it or rasing with it. but i'm sure both are of same class.

Trail bike is love :* How is the power compared to Yamaha DT175? I am a big fan of dirt bikes

[JUNOON007]

Great work bro

[Shafin619]

Yar I saw Yamaha DT couple of time but couldn't get experience to ride it or rasing with it. but i'm sure both are of same class.

My friend restored one but it was enduro 100 he modified it with DT175 parts and replaced its 2 stroke 100cc engine with 4 stroke 125cc malaysian engine.Here is the thread https://www.pakwheels.com/forums/bikes-3-wheelers/243582-custom-made-yamaha-dt

[mbaqurashi]

Next stage was engine rebuilding.
it took tremendous efforts to take apart crank case, because it was jammed by rust.

Piston was missing too, but seller informed me that Suzuki 2stroke carry box's piston is almost of the same size as KE175's piston but only wrist pin's dia was different.

i took cylinder and weight to Meraj Din Kharadia (lathe operator) AKA maaja kharadia @ McLeod Rd. That lathe operator put new sleeve in cylinder and adjust crank-rod according to wrist pin of piston.

Oil seals were purchased from Hamid Seals at Montgomery road.

I rebuild all the engine in my bedroom and reading room.

[ammarzahid]

mashaAllah bro great job

[mbaqurashi]

next, we adjusted its steering. Purchased ball bearings from Nistar road hardware market.

Chrome polished handle bar from Mcleod road.

[mbaqurashi]

After engine assembling, the next problem was its both CDI coils (exciter + pulser) aren't working, first I tried to find them in Bilal Ganj Maket but no success. Then it was decided to repair (rewind) them, so I repaired both coils according to given ohms in KE175's workshop manual.

[mbaqurashi]

After we were done with coils, next challenge was finding correct CDI. I can't simply use Honda or china motorcycle's CDI unit, because Hall effect triggered CDI and pulsar coil triggered CDI are totally different. After lots of tries of different CDIs, I finally decided to build it by myself. I searched over internet for schematics and purchased related parts from hall road.

[ayaz.farrukh]

You are a Champ.

[abzia]

Although DIY in electronics in good, but make sure soldering is done properly, dry solders are hard to find and troubleshoot.

[saboor73]

nice restoration the bike was finished you gave it new life

[mfdarvesh]

Subscribed ..

At same time, you are mechanic, electrician, researcher etc. etc - Good Job

[mbaqurashi]

Soldering was done easily.

Although DIY in electronics in good, but make sure soldering is done properly, dry solders are hard to find and troubleshoot.

[ammarzahid]

very very impressive job

[mbaqurashi]

I kept on searching Bilal Ganj, McLeod rd. for fuel tank, silencer and carburetor, but all went in vain. Mr. Mzhar aka Chitta dentar given me some hope of finding fuel tank but didn't worked. I thought I NEED TO BE CREATIVE. I start searching internet for those who are selling KE175. I found one person on olx selling KE175 Engine, I contacted him and found silencer and carburetor eureka :D. (later I realized that carburetor isn't original, I was crab of RX115 but it worked) .

And about fuel tank, I found a person on pw selling hand made stainless steel trail bike, and found fuel tank with him... THAT IS IT, (kaam ho geya).

[mbaqurashi]

Next stage was repairing of wheels and shocks.

New tubes and bearings were purchased and tubes was installed from tyre shop. I install bearing by myself, Break shoes leather was repaired from Royal park.

Shocks were given to Sabari Shockan wala near Butt Chowk, Ghari shaho road. but that guy didn't repaired them well, front shock's seals leaked after first ride and Rear shocks,,,,, they were shockingly hard. so, it is decided that we are going to repair shocks by ourselves.

[mbaqurashi]

after every piece of bike was ready, we start joining all the jigsaw puzzle together to have a closer look at our efforts.

Fuel tank was later painted into red by Mubarak Painter at McLeod road.