Project Next, Kawasaki F2tr.

So while the paint was drying (see above) I got on with fitting the new gaskets and getting the engine together.

I found a picture of what it should look like when finished.

Will be an eight week wait now for the chrome bits to be done, so until the wheel rims and some other small bits I've ordered turn up it will be having a rest for a while.

 

The new rims and spokes arrived yesterday, so hid in my shed from the cold wind and fitted to the painted hubs.

Fitted back tyre, but will need to buy a new front.

 

Today I needed some 'therapy' so hid in my shed from the cold wind and got a bit done.
Not a bad mornings work.

After lunch I fitted the engine and a few other small bits.

Will look pretty 'spiffy' with the chrome work fitted and the bright red paint.

 

The bike came with a dodgy chain adjuster (from a Suzuki) and attempts to find a correct one on evilbay had not proved fruitful, so decided to make one. I laid the right side adjuster onto a piece of 1.6mm mild steel sheet and traced the outline. (The Suzuki one in background.)

I cut out the rough shape with the guillotine, folded over and welded a piece of 4mm plate to the inside to put a thread through.

Drilled hole for axel and ground to final shape.

A dip in the zincing bath and it looks like a bought one.

Fitted to bike and found I had forgotten to mark the adjuster for axel alignment. No problems as I use a stringline to align the wheels anyway.

 

Todays task was to make an oil cap breather. The old one had been lost long ago and a crappy piece of gauze had been fitted in its place. Cut a new washer from some 3mm neoprene.

I used a piece of 1mm aluminium sheet, the ball end of my hammer and a 22mm socket. Sat the alloy sheet over the socket with hammer on top and gave it a couple of medium taps with a plastic hammer (never hit two steel hammers together as the hard faces may splinter off into you) to form the dished shape.


Trimmed the outer edge to fit the cap, drilled a 1.6mm hole and fitted with rubber washer.

Oil tank now sealed and able to breathe.

 

Cleaned the fuel tap today. Amazing how much crud and corrosion builds up in these when left for a long while.

A run over with the bead blaster soon cleaned it up. Will buy some new seals and all will be well.

 

Drove over to the chromers at Coffs Harbour on Wednesday and picked up my nice shiney bits. Visit to JDK wreckers at Tormina gained me a 2nd hand front tyre (not quite the tread pattern I wanted but the price was right) and some pipes for another project.
Today I started putting the shiney bits on the bike. (Tank and seat just sat on frame for photo.)

Took me a couple of hours to get the exhaust pipe fitted as the chrome had built up the diameters where the two pipes fit together. I had to do a bit of sanding to get them together, and similar with the baffle.
Still some electrical work to finish off and some small bits to be zinc plated that I missed.

 

Thank you.

 

The speedo was the last thing to be overhauled. It had crap on the inside of the glass, and the needle was stuck at 120mph.

I made this little tool from 70mm of 6mm bar. Shaped the end to get under the folded flange of the chrome ring that holds the glass on.

By working slowly around the circumference (three times) I was able to get enough room to get a small flat blade screwdriver under the rim to get it off.

What I found inside was not pretty.

Also the spring that returns the needle was snapped and the gears frozen.

A gentle cleanout and lubrication had the gears working. A dab of solder fixed the broken spring, and with the battery drill and some old cable put a couple of miles on it at 30mph (high on drill).
Satisfied that all was good, I put a dob of glue onto the warning light lenses, checked all bulbs working and fitted the cover. To peen the flange over I cut a 50mm piece of 100nb pipe and shrunk it down to 90mm to sit the top of the flange on.

With the edges filed smooth, I sat the flange onto the pipe and carefully tapped the edge down with a large square ended punch.

Back on the bike and ready for another 50 years.

 

Almost done. Waiting on a couple of small bits and will be ready to fire it up.

A bit of difference in the suspension travel between 1966 and 1981.

 

Last bits arrived Friday and I got it started over weekend. Tank badges arrived today and fitted and went for a 'test' up the street. A couple of small adjustments and all is good.
I consider this one finished.

And here with a couple of friends.

My Kawasaki trifector. One from each decade, 1960's, 1970's and 1980's.

 

Remember this poor neglected thing?

Now this.