Project - Kawasaki Deluxe

[metalhead]

Very good. Keep the pictures coming...

[hidalgo]

Waiting for out come

[daniyalahmad]

Good Going. Nice Project

Thanks mate!

Very good. Keep the pictures coming...

Thanks buddy!
More pictures are on the way.

Waiting for out come

Me too,
Was having problems in finding good quality OEM parts so progress was a bit slow.
Will be winding it up soon Insha-Allah!

[daniyalahmad]

The fuel tank is badly rusted and corroded.
Will be getting another one as the current one is beyond repair.
However we have repaired the side covers because they were not locally available.

And here are the updates about the bike:

Received the front and rear shock covers/glasses from the painter and got them fitted on the bike.

Got new speedometer, the deluxe one was not available and the owner wanted one with tachometer so got the GTO one.
Hoping that it will fit with some minor alteration in the bracket.

Got new tail light and indicators.

Ignition, charging and headlight coils have been re-winded.
Got new wiring harness.
Anyone having the wiring diagram of this particular model then please share the picture of it.

[Xulfiqar]

^ To be very honest, I dont have that much knowledge regarding these 2-strokers.
Another friend is taking care of the engine, got it checked by a couple of reknowed mechanics and they assured that the crank allignment is perfectly alright.
Since the engine was rebuild 3 months back using all OEM parts so its running pretty fine.
However we are having plans of 4 speed to 5 speed conversion but this plan is still undecided.
However will change the cylinder as soon as I find one with bore of STD size or at most 50 size.

I can almost guarantee that the crank would not be perfectly true - the only recommended way is with dial guage, anyway - there are a few tricks/mods to make a two stroke engine perfectly long life like it was from the factory.

Now for the brakes and hubs, remove these $chitty bearings and install 2RS bearings, knock out one seal and install the bearings open face inwards and fill the hub 80% with wheel bearing grease. They will last an incredibly long time. Do the same with the rear sprocket carrier too - it uses a grease seal to keep the bearing grease in - always renew this seal and ensure it rides TIGHT on the spacer.

Now for the frame, I hope you didnt burn the frame to remove the paint.

[Automotorsport_Lover]

Nice goin project! wish u luck! waiting 4 updates!

[daniyalahmad]

Nice goin project! wish u luck! waiting 4 updates!

Thanks for wishing me luck.
Updates are on the way.

I can almost guarantee that the crank would not be perfectly true - the only recommended way is with dial guage, anyway - there are a few tricks/mods to make a two stroke engine perfectly long life like it was from the factory.

Hmmm...
I'll ask the dude to get it checked in the way you mentioned.
I know a person who alligns cranks in the best possible and professional way.

Now for the frame, I hope you didnt burn the frame to remove the paint.

Hahaha!
No no we didnt burn it, the paint was already in a bad state so the wire brush was more than enough to remove the paint.
On bends and unaccessible areas we used sand paper.

Now for the brakes and hubs, remove these $chitty bearings and install 2RS bearings, knock out one seal and install the bearings open face inwards and fill the hub 80% with wheel bearing grease. They will last an incredibly long time. Do the same with the rear sprocket carrier too - it uses a grease seal to keep the bearing grease in - always renew this seal and ensure it rides TIGHT on the spacer.

They have been replaced, have used NTN bearings and there is no seal on the inner side.
They were already greased and very smooth but I'll get the hub greased as per your direction.
Im using Caltex multipurpose lead free grease NLGI Grade-3
Is it okay?
And can you point out the exact place which should be greased in this picture?

[daniyalahmad]

Since the original fuel tank was corroded beyond repair so had to find another one.

My painter got this for me.

Its in a good shape with no rust and the fitting brackets are also intact.

It will be re-painted along with the side covers.

Front and rear shock absorbers have been fit in.

Got new mudguards.

Attached the tail light with the rear mudguard.

Got new drive chain case set for the bike.

[a_k]

^ I always love this part when things start to take the desired shape

[Xulfiqar]

the hub carrier seems to be missing its grease seal or the hub carrier is from some other make, The spacer you see rides on a grease seal pushed into the recess.

anyway, have you installed a new oil pump on the engine? Kawasaki superlube are notorious for being a PITA if not renewed, because I wouldnt advise to use premix on this bike unless you know and are experienced in advance level carburettor jetting and needle selection.

If your frame is missing wiring holding clips you can buy them brand new at shops that sell new nuts/bolts in car part markets, They sell the twist type which are plastic coated. These clips need to be either riveted or spot welded in place, makes for a tidy wiring harness. I also like to use some braided looming for beauty and grommets in the headlamp case to keep dirt out of the case.

[hidalgo]

MA
loving the outcome
how will tachometer work
in my rx 115 its not connected to any coil there is a sprocket inside crank case its attached with though rx is a longresto project but how will this work in saki?
how much ou got speedo for?
and sourcing parts is a bit difficult i know some guys who can be helpful shoot me a pm if u want their numbers

[Xulfiqar]

^^ Kawasaki KH series have a similar setup like the Yamaha RX but its run from the gearbox input shaft, its at the back of the engine and with this round air filter it wont work, the GTO style triangular air filter has a tube inside it that is provided to pass the rpm meter cable through it, as it opens directly on top of the rpm cable port.

[daniyalahmad]

^ I always love this part when things start to take the desired shape

Me too!

the hub carrier seems to be missing its grease seal or the hub carrier is from some other make, The spacer you see rides on a grease seal pushed into the recess.

anyway, have you installed a new oil pump on the engine? Kawasaki superlube are notorious for being a PITA if not renewed, because I wouldnt advise to use premix on this bike unless you know and are experienced in advance level carburettor jetting and needle selection.

If your frame is missing wiring holding clips you can buy them brand new at shops that sell new nuts/bolts in car part markets, They sell the twist type which are plastic coated. These clips need to be either riveted or spot welded in place, makes for a tidy wiring harness. I also like to use some braided looming for beauty and grommets in the headlamp case to keep dirt out of the case.

Yes have found an oil pump in good working condition from the junkyard.
It has been cleaned, checked and fitted.
The oil reservoir bottle was also repaired and checked for any leaks and now the setup is operational.

For the wiring harness there were two brackets on the frame to hold the wiring harness.
For the remaining wiring harness I used these small plastic ties.
Wiring has been neatly secured along with the frame with these plastic ties.

As far as the headlamp case is concerned then I plan to use a bigger headlamp in it.
We have been testing various headlamps and its original one looks too small because of the bigger speedometer and indicators in place.
The best combination was made with the CD 100 headlamp.
Gives a muscular front look to the bike.

MA
loving the outcome
how will tachometer work
in my rx 115 its not connected to any coil there is a sprocket inside crank case its attached with though rx is a longresto project but how will this work in saki?
how much ou got speedo for?
and sourcing parts is a bit difficult i know some guys who can be helpful shoot me a pm if u want their numbers

Thanks buddy!
The tachometer will work with the gearbox shaft.
There is space present at the back of the engine block.
Got the speedometer for 1k.
BTW let me know if you know some one who is having the "Deluxe" emblems for the side covers.

^^ Kawasaki KH series have a similar setup like the Yamaha RX but its run from the gearbox input shaft, its at the back of the engine and with this round air filter it wont work, the GTO style triangular air filter has a tube inside it that is provided to pass the rpm meter cable through it, as it opens directly on top of the rpm cable port.

Naah, there was ample space on the top of the air filter assy to pass the cable of the tachometer.
Have a look.

Tachometer is operational.

[daniyalahmad]

Engine has been fit in and wiring has been done.
Will be getting a new battery tommorow Insha-Allah.

Received the fuel tank along with the side covers and the headlamp case from the painter.

Notice the paint quality and finishing.

New fuel tank along with the old one.

[Xulfiqar]

The cable runs bent in this airfilter setup, anyway - when you tune the caburettor make double sure that the carburettor cover gasket in place. It makes a great difference.

and please do us all a favor and get rid of these junk philips screws from the engine. Use allen head socket screws.

Your painter did an excellent base paint job but what happened when he was painting the graphic? not interested in his job? - The graphic is supposed to be smooth and shiny like the paint. Anyway you are doing good.

The original handlebars for this motorcycle had weights in their ends to reduce vibration to the wrists. If the handlebar is not original and they are not there then find a pair from a larger motorcycle and have a couple of receptacle nuts welded in. It makes a great difference in riding comfort.

[joinami]

[QUOTE=Xulfiqar;3365600]The cable runs bent in this airfilter setup, anyway -

@danial if you require GTO aircleaner box . it is available any tme for you and its not costly ,,mind it and please try to get orignal tail lamp cover,

[star2]

aala project

[raza1]

Beautiful project. Keep posting pics mate.

Sent from my iPhone using Tapatalk

[amirhasan]

fuel tank paint job is really awesome

[haseeb2288]

good going bro