More Bits !!!

Well, today, Tuesday 8th November, MORE bits arrived!!
The new original throttle grip came, and more importantly, the rear wheel spacer arrived. I would have liked to have fitted this today, but, as usual, stupid work got in the way! That and feeling like crap due to a cold bug which Donna, more worryingly, has also got. Ironically, it would seem we caught it at the vets!! Should have got a shot while we were there!
As the weather is also pretty crap this week, I think I'll get it all sorted at the weekend, when the new thermostat should be here as well. I will then be ready to fill up with oil, coolant, and maybe, if I dare, some fuel and give it a kick!!

Bonfire Night

Well, today is or will be, bonfire night, Nov 5th. A nightmare for Mac, one of our hounds, but the other Louie is not botheed with it all.
Anyway, back on the bike front, have now got both wheels on, although the back wheel is missing a spacer, which explains quite a lot, such as, wheel had rubbed away part of the upper chain guard, and the opposing side swing arm. I'm amazed the previous owner actually rode it and stayed alive!!
Anyeay, I've managed to get a replacement, new, spacer from good old E Bay for £6.99, a bargain, especially as they are not produced anymore!!
I'm hoping that it arrives on Monday, then  I can complete the back end. The front end is done, apart fron fitting the front mudguard, or for any Americans, the front fender! I have fitted the speedo cable, new front pads, although I still need to repair the master cylinder. It looks like I'll have to buy a replacement piston assy for it, but it's not expensive.
Have still got trouble sorting the side stand, and have not as yet decided exactly what to do. I've fitted the small replacement one that I bought, as the latest big one ended up to bloody big!! I'll get there though, it may be just need to get a pice welded on to extend the short one, which would be good, as it really is a strong piece of kit.
The chain, which looks almost new, has been bathed in a pool of gear oil, and is now hanging and draining in the workshop. Once the spacer arrives, I can fit the front sprocket, chain, front sprocket cover, and importantly, the neutral switch wire. There is still quite a bit to do, and it's a bit frustrating as money is always a factor, but it is making progress, although sometimes it's one step forward and two back.

New Arrivals!

Wahay!!
Today has seen the arrival of the new Metzler Karoo rear tyre, and a new inner tune with Rim tape.
I fitted the rim tape, and rushed it all round to Frost Tyres, where John soon had it all in one piece for the princely sum of £5.
Well worth it. Now looking forward to friday, when, after taking the dogs to the vets for their kennel cough vaccinations, I shall be getting a lot of stuff done.
Trial fitted the stand to a spare frame lower today too, and it fits perfectly. Hope thats the case actually ON the bike, but I'm sure it can be adapted if need be.

Anyway, friday hoping to fit both wheels, stand, chain, chain guard, front sprocket and guard.
In true Edd China fashion, I may need my mate Paul to help me on that bit as it's quite heavy, but it will probably end up being wife Donna instead!!
If it stays fine, maybe fit some bodywork, in fact it'll be nearly done!! Nah, a bit to do yet, but it's going the right way.

Slow progress

Well, a quick update on slow progress.
I spent a few frustrating hours yesterday trying to rebuild the master cylinder. First problem was that the rebuild kit bore little resemblence to my own piston assy, and was in fact too big.
I assumed that my master cylinder was off a KLR 600 A1, but obviously not.
I now have a bit of a dilemma. I can't really send it back, as I opened it and actually fitted the outer dust seal.
I thought I might get away with the original seals, but after filling and bleeding, there was not much pressure being exerted, although I have no pads in yet, Once I have fitted thew new pads and front wheel, I'll try again. You never know your luck!
On the good side, got an E Mail today (Monday) saying that the tyre, tube and rim tape were on their way. Also, the new side stand arrived from Belfast, and quite a thing it is too!!
Well, here's hoping for an easy day at work tomorrow, and a couple of hours fitting stuff!

Bits..bits...bits..!!

Well, today has seen a few bits arrive at last.


2 oil filters arrived, along with a master cylinder rebuild kit, and a bolt for the front brake lever, which was missing. It's not the correct one, but it'll do the job. 2 oil filters, as I am changing the oil after a few days, and then again after 200 miles, just to be safe. Also arrived, a spanking new NGK surpressed spark plug cap, which looks great, very retro, and some more electrical connectors, as I have used bloody loads!! Oh yes, and 5 metres of solder, always useful for....soldering stuff!


Not fitting anything today, too tired after a busy week at work, so off for a few beers tonight, and then set about sorting the master cylinder tomorrow morning. Have also bought a new rim tape, tube and rear tyre. over £100 but once that lot is fitted, and the replacement stand and front wheel, it will actually look like a proper bike, and aactually, will not be far from finished. Tyre is a Metzler Karoo, not used them before, but they get good reports around the world on KLR forums, so I'll give it a go. Will buy a new Metzler Karoo front when the bike is ready for the road, but the knackered old tyre on the front will do for moving around in the garden etc. Onward and upward !!

Quiet days

Well, today, Sunday, has been a pretty quiet day on the bike front. Not done much as I am now waiting (again) for parts.


I have got a new oil filter coming, a master cylinder re-build kit, and a brake lever pivot bolt + nut.
Stripped the master cylinder, and it was completely yuck inside! Have replaced the rubber brake line with a stainless braided one, which was on the original piece of scrap that I bought!! One of the few (Very few) parts that were worth keeping.
The caliper looks to be in excellent condition, and is not seized at all. I will build up the brake, and see how things look, then I will maybe replace the seal and piston, but it looks like they are all good.
Have cleaned up the rear wheel today, no rot, just some surface rust on the spokes, which cleaned up well with a wire brush on the drill.
I also stripped the side stand that I bought, as I need to get my good mate Harry to do some grinding on it to make it useable. The leg supplied is way too short, but it looks possible to replace it with the original leg. Heres hoping!


We'll see what comes in the post tomorrow, and I'll update after that!

To spark or not to spark!!

"Do you know what you're doing dad? Ha ha!!"

"

Right oh then, the replacement CDI has arrived, along with the replacement Regulator / rectifier.
As today was my day off, I decided to crack on with fitting and wiring everything and seeing what happened. This all had to wait until the afternoon, as the boss had some "Jobs" for me to do!!
Well, jobs done, I ventured outside to the bike, removed the covers, and set to work.


Firstly, I decided to un cover all the looms which I had previously covered, as I wanted to see for definite, which colour was which, and generally check everything was correct. I also had to expose the defunct 3rd generator wire, as I could now wire it into the reg/ rect unit. As the loom is for a 600, I had to make up a new wire for this 3rd output, but it all fitted fine.


Next I found which wires were the exciter coil wires, fitted them, and wired up the CDI. After about 1 hour, it was all done. I fitted the battery. I then felt a little nervous, would I now get a spark? Is the CDI ok ?
Turned the ignition to on, laid the plug on the head, kick...kick...kick..NO SPARK!! Bugger!!
Checked all connections again, all ok, so I decided to try a different coil, which I had bought a while ago, and found was the wrong one. After a bit of bodging about, fitting an earth to it for one, I switched the ignition to on again...Kick..SPARKS!!!!
Hurrah!!  It works!!
So, I now know that all is well, apart from the coil. I will try and fit this new coil tomorrow somehow, it looks do-able, but if not, I'll get a replacement.
At least I can now crack on, didn't want to buy anything more until I knew the thing would at least try and run!!
Tune in tomorrow for updates!!

October Update

Well, it's been a while due to work and boring stuff like that, but here goes again.


After still no sparks, I have tested coil, which is new (2nd hand)  and seems ok, Ignition switch, which is pretty basic and smacks of clutching at straws!! No joy, ie no faults, so unfortunately, it looks like the CDI units, which I have two of, supplied by the idiot. I assumed, though with no real reason, that at least one of them was ok, but have tried both and tested both as best I can, and It looks like they are faulty. Bugger.
So, forlornly, I scanned my good and trusted friend E-Bay once again for said units. After much searching and fruitless watching, I saw that they were going for lots of silly money, or were only available from Slovakia(WHY?)
So, after a break from it all spent researching my family tree, which was good fun, I resumed my E Bay searching, and found a bloke called Steve, in Swansea, who was selling bits from a KLR 650 Tengai.
I sent him a message asking if he had the rectifier / regulator and CDI unit, and if so, how much would it be, and lo and behold he got back to me and said yes, make me an offer. I offered £40, and amazingly, he said yes!! Eureka!!
I paid him immediately, and today, Saturday 15/10, he has posted them .I actually gave him £45 for it all, still a great bargain.
When they arrive, I'll wire it all up as a straight 650 machine, and hopefully I will get many many sparks!!
Then I will set about getting the wheels on, and sorting out a side stand. I have bought an after-market short bolton one, which I reckon I can adapt using the original KLR long stand leg. Time will tell!
Right, that's it for now, off to get ready now for a celebratory beer or 3, although Wales lost at rugby today, and Grimsby Town lost at York City, but I'm used to the latter, and the former was just bad luck!

29th September 2011

Well, been a while, but as we are mid heatwave here at the end of September!!
Spent a very productive and happy afternoon re-wiring the beast! The CDI unit and ignition system is now fully wired up, along with the generator and associated bits and bobs. No problems encountered strangely enough, just a slight bewilderment as the wiring diagrams for 600s and 650s do vary a bit, and as I have a 650 engine including generator, and 600 loom, things needed close scrutiny. Anyway, it all seemed to go together well, I need to get a battery now, as I really need to see some kind of life in the bugger, and a spark would be nice, at the plug only of course!
Have ordered new brake shoes and pads today as well, so they should be here next week. Sadly I'm back at work then, so they may not get fitted for a while, but I'm gonna try and kick on with the bike now. Need to hear it thumping away at least once!

10th August 2011

Well, not been doing much for a couple of weeks, busy setting up the Air Con business.
Have today received a replacement kill-switch, as mine was dead already!
Have also managed to get hold of a very good clean corrosion free front wheel, I may have to find a back one as well, but I'll cross that bridge when I come to it.
Did a bit of dabbling tonight, painted the exhaust down pipe with high temp paint, looks a lot better than it did, also fitted the upper chain guard.
Fitted a 2nd hand coil as well, but not entirely sure if it's in exactly the right position. I'll have to have an in depth investigation at some point!
Need a nice sunny day now, with no work, so that I can concentrate on finishing the wiring loom. Got the CDI unit to fit and wire up, also the rectifier regulator. The alternator on the bike is 3 wire output, and the standard rectifier only has 2 inputs, so I'll just cut one off and try it out.
If it doesn't work, I have another 3 wire rectifier, which I could fit, but not sure of it's output, and don't want to boil the battery, assuming of course that the bugger runs in the first place!!
That's all for now, coffee waiting..

23rd July 2011

Well, the forks are back, and although I moaned about the price, it looks like it was worth it, they look great as Mick has given them the works, clean up and all. Will fit them today along with the front wheel and headlight framework (Once I've got it painted), then at least it will be moveable, well, sort of anyway.

Starting to take shape

Forks fitted

22nd July 2011

Well, decided to service the front forks, as I had re fitted the yokes the other day, the old bearings were ok, so fresh grease was enough.
Took the forks in to Owen Cherrels, as the bolts at the bottomwere incredibly tight and seized, and I would have only ended up damaging them and probably me in the process.
Left them there hoping they would remove said bolts and fit seals, then I could do the rest myself, clean out, new oil etc.
Rang me tonight to say they'd done the lot, seals new oil cleaned out....£90 bloody quid!!!
I was hoping for £50 tops, that's all I wanted doing...jesus, why can't people listen!!!
Ah well, it's done now, so tomorrow I will have 2 brand new forks, and 90 quid less in the bank!!
Ought to go to bed and turn the computer off to save money now!

Sunday Spannering 18th July 2011

Today has been a good day in the 'Man Shed'!
Have fitted the new clutch, new plates and springs. Had to re-tap one of the bolt holes, as I wasn't quite happy with it, but it's fine now.
Also re-built the water pump with new seals and fitted the clutch cover complete with new gasket and kick start seal. Also managed to spray it with satin black, which looks quite good really. Must get Donna to take some more pics to go on here.
Tomorrow, I'm hoping to start rewiring, but if the mood doesn't take me, I may strip the forks instead. Either way, it's better that being at work, off this week, hurrah!!

Louie lending a hand

Spring fitted

Looking good

In the beginning!

Kawasaki KLR 600 Project.

 

After buying the bike from a very chavvy looking lad in Rushden, following a hairy journey down with Mad Harry in his van, the KLR arrived safely in Grimsby.

It is an understatement to say that it was not quite what I expected!!

I though give it a month or so, should be on the road…not a hope in hell! This is a major re-build case.

The wiring loom has been destroyed, presumably as the previous owner used it as a “Field bike” (WHY??).

He was running it straight from the generator and Cdi unit, and destroyed the coil in the process.

It looks a LOT better in these pictures than it actually is!!

Right, best thing to do is to strip it right down, see what needs doing and sort it from there.

So begins the tale!!

Everything came apart in a fairly straight forward fashion, down to the frame and swing arm, which were still attached to each other via the swing arm pivot bolt. This bolt is now called “bastard!!” Nothing would persuade bastard to move, heat, more heat, hammers of various size, shape and impact, not even copious amounts of WD40 and curses!!

So, in the end, only one thing could be done, cut the bugger off and replace the

whole lot.

Replacement Swing Arm and shock Whoopee!!

The shaft bolt, spacer and nut, brand new comes  to £138!! No way!

After a lot of searching around, finally found all the parts in Sun City, California, and they shipped them over for £80 or so. Nice!

Second hand Swing Arm, complete with arms was sourced and a replacement shock, although, the shock does seem to damp correctly but the bump stop has perished away to dust.

The bearings seem good in the new swing arm, but I’ll replace them anyway when it comes to it.

First job is to get the frame sorted. The locating lug for the side stand has been broken off, fortunately, he kept the stand, with the piece attached, so I’ll get it welded back on. Then it’s off to CJ Powder coaters, to have the whole lot blasted and hopefully coated, but I’ll see how much it will be first.

A side issue to the project is that I sent off for a new log book, as the chav had “Lost it”, and I received a letter today that the vehicle is recorded as being scrapped!! This caused great consternation, and after filling in the form that they sent me, I decided to ring them to see where I stood with the bike.

A very helpful lady at DVLA Swansea informed me that, although the vehicle had indeed been “Scrapped” on their system, it was by the previous owner,

not through a breakers yard, and so there should be no problem getting it back on the road! Phew!! That made me (And Donna) feel a LOT better


The workshop is now a mass of parts, and a scruffy looking lump which could pass for a KLR engine, although it was half blue, as the chav had rebuilt it with instant gasket, it was EVERYWHERE!!  KLR’s are known to not tolerate large amounts of sealer, the oil pick up screen is easily blocked, and havoc usually ensues!

Well, while I waited for the bits for the suspension to arrive from the USA, I decided that it would be a good idea, in view of what I’ve seen of this “mechanics’” work previously, to take the head off the engine, and check out the lump.

First off was the cam chain tensioner, cam chain off the wheels, and then take off the cam journal caps. Preparing myself for the horrors that may lie beneath, I lifted the cam caps off and….hmm, not bad!!

Both cams seem ok, one exhaust lobe is a bit tarnished, but no pitting anywhere, and the bearing journals look fine.

He said that he had replaced the cam chain last year, and I believe him now, as the tensioner was hardly out, and the chain is excellent. So far so good.

Next off, the head. Came off without incident, but, hello, our friend has renewed his love affair with instant gasket, and has used it to repair the head gasket, instead of wasting a tenner or so on a new one!! At the same time, he managed to gum up 2 of the water channels in the head / barrel, what a complete tosser!



Looking into the cavernous bore, the piston lurked below, and on inspection, looked fine on the crown, best get the barrel off and check the skirts and bore it’s self. After a bit of gentle persuasion, off came the barrel, and to my amazement, not a mark on the piston skirts at all!

The bore had however, got some very small amounts of surface rust on it. I imagine that the ‘repaired’ head gasket has failed spectacularly, and water has ingressed and caused havoc. The top and second compression ring were seized in their grooves, probably also due to water. The scraper ring was ok, but there were a couple of rust spots on it, so new rings will be the order of the day.

If I can find somewhere local that can hone the bore, I’ll get it done, otherwise it’ll have to be a fine gentle rub with wire wool.

Well, being Sunday, that’s all I could do at that point, but I had sockets in front of me, and nothing else to do, so what the hell, lets get the clutch cover off and see what we can find!!

Without further ado, the many 8mm bolts were removed, and with a couple of clonks with the mallet, the cover was set free!!

By looking at the old gasket, it was obvious that the idiot had not had this one off, not a sign of blue stuff anywhere for a start, and everything was clean in there. Seeing as I was in there, it would be foolish not to rip the clutch down and check it over. 5 bolts and springs came off easily, and then the plates followed, well, what was LEFT of the plates! Absolutely worn out, thank goodness I’d checked them. Maybe .25 mm of material left on them, should be at least 2.65mm.

So, now the shopping list is, piston ring set, full gasket set, clutch plates, and a few seals for kick start, etc.

Hope to get some prices on those this week, and get started on the re-build soon!

Well 2 weeks have now passed, and I have got a replacement pivot bolt for the swinging arm, from a guy in Germany!! That’s everything I need now to re-build the suspension, apart from tarting stuff up with paint etc.

The gasket set and rings will be the next step, and then the engine can be built up again. The bore has been honed lightly, and looks very good. Think I’ll give it a good clean up outside, and give it a coat of HT paint to finish it off a bit, the head too, once I strip it down and replace the valve guide seals. Also needs the seats grinding in, but until I get the gasket set, not much point in starting. Could do with a nice lottery win!

One job I got done was to lengthen the leads of the CDI unit, which were soldered to length, and each joint heat shrink wrapped, then the whole lot wrapped in insulation tape, nice and cosy!! Job done!

I’m going to re-wire everything once most of the bike is re built, as it will be easier to see how long things need to be, and where the best routing goes, and where to mount any earth’s points etc.

I can at least now get to work on the old pivot bolt, knowing that I have a replacement, so I don’t have to be too careful! Will get on with that tomorrow afternoon I think (Wed 6/4/11).

Well, after a long break from this journal, due to hard drive destruction, latest update!!

The stand bracket didn’t get welded back on, as the welder, poor old boy, couldn’t work out how it went !! I did point it out, but never mind. I’ve found a bolt on one, which I’ll get at a later date. He did however get the offending Swing Arm Pivot bolt out!! Hurrah!!

The lower frame, on inspection was found to have a couple of splits in the tubing, which I didn’t like the look of, so have got hold of another from E Bay for 26 quid.

Decided against powder coating, mainly due to the cost, so stripped back to bare metal, etch primed and then 3 coats of gloss black, followed by 2 of lacquer. Looks good, and a LOT cheaper. It’s not a showroom condition bike, so it’ll do!

On the engine front, have reground all the valve seats, and fitted new valve stem oil seals, have sprayed head, barrel and engine crank cases with matt black barbeque paint!! Looks great!

Bought a new set of piston rings, new KACR valve spring, and full gasket set. Still need mechanical seal for water pump, thermostat, (As the idiot ran it without one!), and probably some shims, once I get the engine together again. Checked the balance chain tensioner, and its fine, so won’t bother doing anything to it.

I managed to pick up a load of engine bits and bobs from a guy in Ely, on E Bay, for £21, which included all the plugs from the wiring loom, so that will be useful later. Also, set of crankcases, honed, gearbox, clocks, rear hub, and much more.

Should save me a fair bit once I begin putting things together rather than taking things to bits!

Well, today, Monday 30th May is a big day, I’m starting to fit things!!

Fitted the new piston rings, no problems apart from where thee should be an ‘N’ stamped on one compression ring, mine have an ‘R’ stamped on both!!

After a bit of research on the interweb, I found that the shinier one goes at the top, with both rings ‘R’ side up. Never one to make things easy, thanks Kawasaki!

Anyway, said rings were duly fitted, and then the cylinder slowly slipped into place on top of a new proper base gasket, with a thin smear of instant gasket for insurance.

Then the next job, re-fit the head, and here comes another problem! The cam chain guide is help stead by a rubber damper, did I remove one? No, our friend obviously decided that Kawasaki didn’t know as much as him, and left it out!

Great, I now have to order a new one, which will prob take a week to arrive now. Never mind, I can get on with other jobs, gonna paint up the clutch and generator covers next I think, then get a new set of clutch plates, and she’s ready to go!

Now 20th June, and a few things have come together, not as quickly as I had hoped, but money and delivery of bits has slowed things as usual.

Got the damper ok, and fitted with no problem. Head fitted, timing done and shims adjusted, had to buy 2 shims, 235 from Robspeed for £3, and 245 from Cradley Kawasaki for £12!! Bit of a rip off, but they’ve got me over a barrel, as there wasn’t one that size anywhere.

Also discovered that in the full gasket set, there was no cam chain adjuster gasket, so not quite full then!

Got one from Robspeed for £4, so that sorted that.

Came to fit the nice matt black finished cam cover..hey up..what’s going on?? Bit wibbly…ah, it’s just slightly different from the original one, (a 650 one). Bugger..ah well, the 650 one fits, so on it goes. Not as pretty as the 600 one I had tarted up, but at least it finished the top end.

Then fitted the generator cover, complete with it’s gasket and voila !! The left side and top is done at last!!

Next job will be to rub down the clutch basket arms, as where the idiot had been bump starting it, it has marked the arms slightly. No use fitting new plates until it’s all nice and smooth. Then I need to buy the new plates, already have the gasket, and nice new seals for the kick start shaft and gear selector shaft, so as usual, it’s now waiting for some spare pennies again!

Did manage to buy a few bits off E Bay though, namely 2 black rad shrouds, one perfect, one with a small bit of damage at the mounting, but will be ok. Also got a nice rad cover from a place in Germany, and managed to buy a helicoil kit, as I think I will need it…also a circlip kit, which I will use on the suspension links. Got to be better than the clips supplied.

Also managed to get another linkage set from the same guy I got another shock absorber from, hopefully this will fit properly. The one I have does not fit between the frame, I have no idea why, it must be from a different model. The new linkage arrives tomorrow, so that will be interesting to see.

 New linkage arrived safe and sound, excellent, and with the elusive big bolt that holds the damned thing together!! No nut though, so I may have to buy one, another £5 +p+p talk about money pit, this bike is worse than any woman!!

Mechanical seal and o ring for the water pump should arrive tomorrow (2nd July) so that’s another little job to complete. It’s getting there slowly. I still need to order a set of new clutch plates and springs. I ordered them from “The Fast One”, surely some kind of bizarre joke, would take 7 to 10 days as their warehouse in Swansea has burned down!! WTF !!

I will order them from WEMOTO, where I got the pump bits from, as they are quick and reliable, if a little bit dearer, but at least they haven’t burnt down yet!

Well, plenty has happened now (12th July), but not that much further on really!!

New bearing were sourced from a supplier, half the Kawasaki price as well. With the use of a heat gun, grease (lots) and a drift with accompanying hammer, the bearings slipped into place in the swing arm. The pivot pin was then fitted, with washers, seals and circlips, and there ya go, one suspension unit!! The swinging arm and suspension is attached to the frame, although I have to jiggle things around again when a new left foot peg assembly arrives tomorrow, as they mount through that.
Then it,s a question of slipping the engine into the frame, torquing everything up, fitting the bottom frame section and then everything should be good, with hopefully no play in the suspension.

I then need to finish the engine, new clutch, water pump seals etc, gasket and clutch cover, with new kickstart seal, and that will be a significant leap forward.
Watch this space!!