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Project Next, Kawasaki F2tr.

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Murdo, Jul 12, 2015.

  1. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    About 18 months ago I rescued this 1966 Kawasaki F2tr.
    Kawasaki F2TR 024.JPG Kawasaki F2TR 026.JPG
    I have been gathering parts when and as available. Today (being such a cold miserable day) I started on the strip down. I had removed the barrel last year using a modified puller.
    F2tr 005.JPG
    This was what I found.
    F2tr 008.JPG
    Nasty!
    Today I removed the engine from the frame and began the disassembly. The generator rotor came off easily (bit different to the YDS-5 last year(see post)), but was surprised to see rust on the clutch.
    F2 engine 008.JPG F2 engine 007.JPG
    This is what a blown crank seal looks like. Note the tell tale dribble of oil.
    F2 engine 009.JPG
    The crank bearings are cactus, as it the conrod and piston. Have new bits ready to go, just need a good clean up and press in the new bearings.
    F2 engine 011.JPG F2 engine 013.JPG
    So, any offers to eat anything strange this time?
     
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    Last edited: Jul 12, 2015
  2. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Looks like it was left half submerged in a river... or mud.

    Eager to see the finished product with your usual attention to detail :thumb_ups:
     
  3. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    No Linkin, it sat in a leaky hay shed for 20 years.
     
  4. Grasshopper

    Grasshopper Well-Known Member Premium Member Dirty Wheel Club

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    Nice one, I like those bikes from that era :thumb_ups:
     
  5. Phil

    Phil Senior Member Premium Member Contributing Member

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    Your reputation precedes you, no takers as appetite lost.:confused:
    Once again I am amazed with your latest endeavour, does nothing stump you ???
    I look forward to watching with great interest the "rebirth of the F2tr."
    Next year the bike will turn 50......knowing the good doctor, it will come out like new :thumb_ups:
     
  6. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    What, no appetite????
    A few things have stumped me in life. Marriage (but I raised my two kids alone), a stone picker I was building and my Canon camera that I replaced the lens mechanism but still not working (bought new one). I consider Phil, that if somebody built it in the first place that I can rebuild it again. :D
     
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  7. risky

    risky risky

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    honda ca77, megelli x2,fzr yamaha x 5 ,maxim,cb750.cb600 hornet,zxr250,marusho magnum electra.
    A TRUE MAN.
     
  8. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    My Bike:
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    Started on the crank today.
    First I tried pushing the pin out cold using my 12 tonne press-no go.
    Then I got the oxy torch and heated the flywheel-no go.
    F2tr crankshaft 001.JPG
    I was actually bending the bed of the press, but still no movement. I thought it was getting dangerous so I decided to get the 9" angle grinder and cut the pin.
    F2tr crankshaft 002.JPG
    I again tried to move the pin halves-no go. I fired up the plasma cutter and blew a hole down inside the pin so as to release some of the pressure. This allowed the pins to be pushed out.
    F2tr crankshaft 003.JPG
    I blasted the flywheels and cleaned up with emery paper in the lathe. All clean ready to be assembled with the new bits tomorrow.
    F2tr crankshaft 004.JPG
     
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  9. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Crank together and in today.
    Pressed the pin into one half, then assembled the rod and bearing and pressed the other side down until I had the recommended 0.25mm side clearance on the thrush washers.
    F2 crank 001.JPG F2 crank 002.JPG
    Using my home made 'V' blocks and a plastic hammer, I surprised myself by getting the crank within the limits (.035mm to .040mm) in two hits. Some days things just go right.
    F2 crank 003.JPG
    I cleaned and blasted the cases, fitted new bearings and seals and assembled the gearbox.
    F2 crank 004.JPG
    Crank back nice and snug.
    F2 crank 005.JPG
    Just need a couple of small nuts to finish off the 'box, a fine day to paint the outer cases and it will be ready for a frame.
     
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  10. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    What do u 'blast' the cases with?
     
  11. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Glass beads at 50 to 70 psi. Gives a 'factory' finish without damage to the surface. When engine together I clear coat to seal the surface.
     
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  12. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Next time its on the job list Ill have to come around and take a look :D
     
  13. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    With the sun out today I was able to get the engine sidecases painted.
    TADAMC Rally 15 002.JPG
     
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  14. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    That looks ace
     
  15. Phil

    Phil Senior Member Premium Member Contributing Member

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    Looking good, has your barrel showed up yet......you must be getting close to re assembly time??
     
  16. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Scraping, degreasing, blasting and washing of the frame parts today. Have blasted all the smaller bits I could fit in my blast cabinet and primed them ready for some colour. Will take the frame and swingarm to the blasting people on Monday.
     
  17. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    While in Bunning's today I picked up a 2Kg bottle of caustic soda to clean the exhaust before being sent to chromers.
    sales 003.JPG
    I put an old spud (potato) in the end and clamped to the frame jig.
    sales 004.JPG
    Mixed the 2Kg with 5 litres of COLD water (don't use hot or it will fizz up everywhere, very dangerous) and poured into the pipe.
    sales 005.JPG Will leave for a couple of days and get the pressure washer to blast the softened carbon out.
     
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  18. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    Have blasted the crap out of the pipe and packed ready to be sent to chromers.
    When I pulled the brake backing plate apart to clean ready for painting I noticed that the skew gear for the speedo cable was missing.
    f2 002.JPG
    A flea bay and interweb search has turned up nothing. I was about to give up when I remembered I had a Suzuki TS wheel with the speedo drive. I removed the skew gear to find it was not just a drop in fit. The teeth matched up ok, but the bearing surfaces were wrong.
    f2 003.JPG
    I had to machine up a new bush with a press-in fit, then offset drilled a hole for the shaft (so that I could adjust the meshing of the teeth).
    f2 004.JPG
    With some washers to pack up the end float and a slab of black grease it went together.
    f2 008.JPG
    I then modified the end of the new Kawasaki cable to match the Suzuki drive.
    f2 005.JPG
    All together and waiting for new rim and spokes to arrive.
    f2 009.JPG
     

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  19. MashtX

    MashtX Well-Known Member

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    One day I hope to be half as good as you Murdo :D that looks ace!
     
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  20. Murdo

    Murdo The Good Doctor Staff Member Premium Member Ride and Events Crew Contributing Member

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    It has been a nice day here today (after a cold start) and I have been out with the sandpaper and spray gun.
    Now I usually don't go in for 'modern speak', but this is an exception as I think this looks Friggin Awsome!!!!!
    F2 bits 002.JPG F2 bits 001.JPG
    The colour looks a lot better in the sunlight.
     
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