B1 resto

Dave · B1 resto

ok, decided to have a play with the box of bits I've aquired. First job was to see if it would turn over, so stuck the kickstart on and..........nothing.... mmmmm? right thinks I, lets have a go at selecting gears,so on with the linkage and......nothing... double mmmmm? Only one thing for it, full strip down and inspection..heres some pics...
engine on bench

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Cases split

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kickstart mech removed to show sellector forks in the wrong place.

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broken kickstart pinion holder lying in bottom of gearbox

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broken kickstart pinion holder.

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malc87

so much for the rebuilt engine :shock:
the bloke must have been absolutely clueless .
still, piece of mind in doing it yourself :D

Dave

hi malc, not as bad as it seems, just needs putting together correctly and a new pinion holder, now its down though, i'm wondering if its worth a recon crank as one main is a bit rough..any tips were to go for this?

g6mow

http://www.kawasakitripleparts.com/RECONDITIONED-CRANKSHAFTS

In stock off the shelf :D

The Wolfman

Oh dear it has met with some ruffian, at least it's in good hands now.

simonh

not a brilliant picture dave, but those selector forks look very untarnished mate, bit of a score with 250's normally screwed

Dave

Dave

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not a very good pic but it shows the diferent wear on the 3 forks.

simonh

defo nearly new or new them mate

main one doesnt look too bad, i've never managed to find a NOS one yet, i've got tuther two NOS tho :D

Dave

got me barrels back today, first over size and honed to match the new pistons :D going to get the crank recond as soon as funds allow :roll: but one question, should I be able to select all 5 gears by hand (engine on bench) or does the 4th gear need to be spinning to allow engagment? I can only select 1st and neutral at the moment....anyone help?.........Thanks Dave.

simonh

not really, pretty difficult to get all gears, especially if the cases are split.

I find that all gears can be selected 'notcherly' if you spin the clutch shaft and final output shaft backwards and forwards. quite often there seems to be a massive false neutrl between 4th and 5th. thats definately not there when on the road

BIG AL

Dave

Hopefully I will be able to spend some time on it this w/end and try your sugestions...Thanks..dave.

simonh

DONT FORGET TO ALIGN THE KICKSTART TANG IN THE HALVES, need some tension on it, but you can 'wind it up' after, providing you can get the stopper bolt undone (normally fooking tight)

Dave

Will do mate, thanks for the tip. Just need to get a pinion holder sorted and then save up for a recon crank! :shock:

Dave

simonh

nice one :D

g6mow

Dave how is life with a KH compared to a Fizzy !!!! :D

Dave

Now on a roll after the gear box success I decided to do a loose assembly of some frame parts to see whats missing etc. Couldn't resist fitting the Microns on :lol: :lol:

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malc87

wd 40 lasts >>>>>>>>>>>>>>>>>>>>>>>>40 days
so i was told

malc87

wd 40 lasts >>>>>>>>>>>>>>>>>>>>>>>>40 days
so i was told

Dave

Dave

The Wolfman

The Wolfman

By the way if you have a later gearbox, or even a 400 gearbox, it won't go up into second from neutral unless the layshaft is turning (ie bike moving).

Try setting the gearbox into 5th by hand then see if you can go down the gears using the gearchange mechanism, its not easy to do it on the bench anyway.

Dave

mmmm.. bike was first registered Nov 76, Eng. number begins S1E and frame begins KH250B. Not sure if this makes it a later one or not? Thanks for the advice, will deffo try the 5th gear test tomorrow...Dave.

malc87

daves bikes is a fairly early b1 about 3000ish off the production line

simonh

i know it'll actually attract water after intial dispersion

The Wolfman

Turns to rock after a while too.
Although it comes off fairly easily.

Dave

Sadly, progress has slowed a bit due to some recent job changes at work so the project is now going to be built as a runner hopefully machanicly sound but a bit cosmetically challenged :) :) until I can splash some more cash at it. The gearbox is now shifting through all its gears on the bench..big thanks to all who ve helped :D :D and Ive managed to call in a favour with an engineering mate regarding the crank rebuild. (mates rates, will be done in between jobs 8) ) Have spent a bit of time cleaning the carbs out
Before..

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After..

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ja-moo

I got spanked on another board about WD-40. It seems the real meaning of the 40 is it was the 40th test formula they ended up using ........ :roll:

The Wolfman

And I heard that WD was for War Department, nothing to do with Rockets.

Guest

some one told me it used to be called "Rocket WD40"and was made by the "Rocket Chemical Company" in America....still nowt to do with rockets though :lol: :lol: Suppose to be quit good for Arthritis to!! :o :shock:

Dave

Dave

Got a call to say my Crank was ready

so decided to crack on with the engine re-build

Kickstart tang and Pinion holder in place

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recond crank in. (primary gear tightend to 85ftlb prior to fitting, less chance of twisting crank)

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Cases closed and Oil pump gear bolt (dont over tighten)

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Ready to fit top end

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Ready to refit to frame.

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malc87

nice work dave

BIG AL

Very nice work indeed dave , now i know where to drop mine off

Cheers
Al

180kid

if i come round now we could have that up and running for the rally............tomorrow,
see ya at the next one,. good job

scouse

nice work
hope you wound the kickstart before you put the clutch cover on

Gary T

Dave

Thanks for the comments guys. Ive now re- fitted the motor, stuck some 20:1 premix in the tank and wired the oil pump fully open, Half a dozen prods on the kickstarter (by hand) and she was away....straight to 6000rpm!! I shut it down with the kill switch pronto! I knew I should have took more time routing those throttle cables

anyway no harm done thanks to the pre-mix and the Microns sounded lovely!!!!

Big THANKS to everyone thats helped with parts and advice so far as I couldnt have got this far without you

Next, I'm going to start on the frame and suspension as soon as funds allow. Will post some more pics soon...Dave.

simonh

still time to get to blackpool mate

Dave

Have rebuilt the carbs now, and have them set up and running on the bike (not able to road test yet though) but the left hand side one (in the picture) has a slightly damaged intake, the air box rubber seems to be sealing ok but does any one know if it is liklely to cause me problems later? All comments/advice welcome.

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Next up I decided to have a go at the seat base. I'd picked up one of those spike strip kits at the Donnington show as the originals had all but rotted/snapped off. I wire brushed the base then painted it with rust killer/converter then primed it and rivited on the spike strip.

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Added a bit of fibre glass and have left it to cure.

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Cheers Dave..

simonh

try spraying wd40 or similar on the join if revs rise you know its sucking it in

Dave

Will give that a try tomorow Simon, thanks...Dave

Dave

Not been able to do much recently, but heres a link to you-tube vid of it running.

http://www.youtube.com/watch?v=fXIokqM1RIA

malc87

nice effort dave,im well impressed