New Project

They're intentionally randomly spaced so it can't generate a harmonic and therefore "sing." This may have been a "non-issue" I don't know.

The man does do amazing RESTORATION in the old school tradition.

Keep it up, Wiz and keep the pics coming.

 

One of the rear indicators was completely rusted out.
I could try to find a replacement, exactly the same, possible, though difficult, or I could buy 4 new or used matching, or I could make a new bulb holder.

 

Wiz, you are amazing. keep the pics coming & love your work, it is insperational.

 

I was watching this thing on 60 minutes about how cubans got harleys back in the 60's and since that ban on anything cuban, they've had to make parts from tractors, cars, what ever, wiz are you sure you're not a cuban?
BTW how did you cut that metal? i may need to do some fab work for my rear tail light

 

Did a lot of drilling with a 1mm bit, then some surgery with a jig saw (fine metal blade) finished on the bench grinder, the hardest part was getting those tabs bent just right.

 

Wiz you are indeed a practitioner of the true art of RESTORATION. I would have scrounged another unit from a salvage yard and gutted it for the bits, but that would have been too easy. Nice work!

 

Rear Wheel ERRRK. :cry:

 

Rear brake finished.

 

wowzers....

 

Rear wheel "before" = OMG I will say it again, this HAS to be the CRUSTIEST nasty dirty neglected bike I've ever seen.

Rear brake "after" = More outstanding work, my friend. Soda blast?

 

The inside of my 750's rear wheel looks about like that "before" picture. I hope mine comes as clean!

 

No, elbow grease.

 

Had some luck at the wreckers yard, found a left side cover, with badge, HT lead fittings, clutch cut out switch & headlight rim c.w. lens, albeit the rim had a male lip, as did my bucket, so I emasculated the bucket, will pos pic' when the paint dries, oh, & a rear tire. That cover has to be the standout.

 

More before pics, swing arm & final drive & motor.

 

Now you are just teasing us as we now sit here in anticipation for the after pics.

I'm gonna say it again, but your work and this thread is inspirational and I think should be a must read for anybody who seeks confidence and/or motivation in their "old bike fixin" skills. It makes ME say, "You know,,,, I would be happy with myself if I could do even half as good of a job on my XJ."

Well done, Sir

 

ooohhhh i cant wait to see that engine, it will look like it was left in a crate form the factory and forgotton about when you're done..
btw, how many miles are on this bike?

heck with wiz's work, if he bought a NOB speedo with 0 miles, people would beieve him that this bike is brand new, at least i would..

 

For you Schooter. bike has 78646 Km which = 48878.806712 miles.

 

damn! thats worn out.. are you completely rebuilding the engine?

 

Don't be silly, Schoot, this is a K A W A S A K I the motors are good for twice that mileage, but we will see, the bike wasn't complete when I got it & so I don't know if it will run, I will have to put the thing back together first & I wouldn't rule out having to pull the lump again.
In Australia the bikes are ridden 52 weeks a year, unlike you guys in the snowy North, who wrap them up for most of the year. :lol:

 

Rear wheel & headlight finished.

 

Very nice! You are going to get some new skins once you get it running aren't you? That looks suspiciously like the same tire as in the "before" pic...

Can we get a close up of the headlight assembly? I'm interested in your "sex change" handiwork on the housing/rim.

 

Hey Wizard what's your address I have some rims to send over the ditch for cleaning :lol:

I take it you did more than just clean and polish?

 

WOW! 8O

 

holy poop

 

I did change the bowler, this one isn't new, but it has got tread!
Upstand lip, arrowed in picture, removed. (for Fitz)

 

you are truly a wizard! any chance your planing a trip to canada! i hear Calgary is a nice place to stop and visit and... work some of your Aussie voodoo on my max! you know the normal vacation stuff! :roll:

 

Frame prepped for welding.

 

Engine mountings finished. Unlike the XJs, these mountings contain shock absorbers.

 

Engine after $100 worth of 'soda blast'

 

wow...

 

XJs have similar shock absorbers, they're sunk into the engine castings rather than being separate like your Kaw.

Finally some soda blasted stuff! Looks phenomenal.

Interesting how the cam chain housing follows the chain contour so closely especially compared to the XJ motor.

As always great work my friend.

 

Yes, you are so right, Fitz, these are just more contrived. Wiz.

 

Look at the state of that flywheel :cry:
It seems the cause of this bike's demise, was the oil seal to the gear shift shaft, The Kawa' dealer is rushing me out a replacement,(4 weeks) 8O
Ideas needed, the hole in the casing (shown x) has been worn slightly oval, it does not have a bush that can be replaced, so how do I repair it?

 

Drill it out as little as possible and still make it round, then use a slightly oversized O-ring? (Is the seal a ring?)

EDIT: Or drill it out and insert a sleeve?

 

There is no seal Rhys, it just guides the outer end of the shift shaft.

 

OK, now I'm possibly confused too. You said the oil seal failed and the Kawi dealer is getting you a replacement, where is that seal in relation to the "ovalized" hole? If the hole in the case is outboard of the oil seal (like the XJs?) then I understand. So the hole in the case just serves to keep the shift shaft from flopping about? How about scrounging a bronze bushing with an ID to fit the shift shaft and sinking it into the cover? It would be an improvement over the OE running directly in the metal. The Norton has some sort of more robust metal where the kickstart shaft (massive by comparison) goes through the case.

Or: Use JB weld or the like to build up the area, grind it down and rebore it and it STILL might be stronger than just running it directly in the case.

It should have had a bushing to begin with if it was ever going to wear out. The Japs simply never expected that poor thing to have such a long life.

 

Yeh, Fitz, it should have had a bush, it does take some stick, I have reformed the holes in brake / clutch levers with Q BOND + JB WELD, so might go down that road.

 

My speedometer adventures and the fork boot thing reminded me these things ALL used a lot of common sizes for things... You should be able to find a bush with an ID to slip on the shaft, then just drill the cover, use red loctite to set the bushing, and grind it off flush.
OR... if you can get the part completely off, take it to a machine shop, and have them drill/sleeve/bore the hole. It's so small I'll bet they wouldn't charge much.

 

I can't believe that Wizard has stooped to asking for help on one of his projects! Or maybe he's just humoring us. Judging by the work he does, I thought Wizard would just part the ocean, drive his bike to Japan and pick up a new cover.

 

sshhhh

 

Don't get all bitchy, Ranger, just 'cos you've got frostbite of the gonads. :wink:

 

I was just throwing you a compliment. I'm sure you'll figure out a fix for the case. I do have a bad case of PMS though! Parked Motorcycle Syndrome. I'll be OK once I see the first patch of grass in the sea of snow I call my back yard.

 

Have someone AL weld the hole and re-drill?

 

Compromise on the alternator casing. I found that the road rash was so deep that it had in fact penetrated the casing, allowing water ingress, hence the rusty flywheel. The bottom half of the casing therefore could not be pollished, the holes were filled with Q BOND, then rubbed down, filled & sprayed silver, the top half pollished in the normal way & the straight masking line of the paint made less distinctive. The badge was sprayed black gloss enamel & the letters picked out with a KRYLON silver leaf pen.
Not perfect but perfectly servicable.

 

Wiz,

They say that if you travel far enough, you will eventually meet yourself. If you happen to know where your counterpart lives in the US of A, please give him my e-mail address!

Alternate: If you're in Missouri and need a place to crash, you can sleep on my couch (it's actually the best place in the house) in exchange for restoration tips.

 

Frame finished.

 

man... i cant wait....

 

More progress.

 

looking pretty tight....

 

Gasket making. :roll: