95 K75 Kafe' Racer Project.

[frankenduck]

All of that spray paint is going to throw the clutch assembly out of balance.

Did you consider getting it media blasted?

[JimVonBaden]

I didn't even consider removing it. I don't have an alignment tool, and it is not going to hurt anything anyhow.

[frankenduck]

You don't need the alignment tool. (I have one and don't use it.)

http://www.kbikeparts.com/classickbikes.com/ckb.tech/0.ckb.tech.files/clutchnospecial/clutchnospecial.htm

If it were me, on a bike with that many miles, while I have the trans off, I'd pull the clutch apart just to measure the clutch plate so that if it's near the end of it's life then I could replace it (or at least know how much life is left.) Min spec is 4.5mm. New is 5.55.

It might also not be a bad idea to replace the clutch nut O-ring with a Viton one. (19x4)

The six bolts around the perimeter that hold the clutch together can be sticky. Use heat and a good Allen wrench when removing them. They have shallow heads and can strip if you're not careful. DAMHIK

IN THEORY, you're supposed to replace those six bolts and their lock washers with new but I re-use the old ones and it's never been an issue.

A mini nail puller can be used around the perimeter to pry the clutch apart:

https://www.ebay.com/itm/254451833276

[JimVonBaden]

Project is on hold as I refurb a flipper Kawasaki Versys.

https://www.kawasakiversys.com/threads/barnish-find-2009-versys-650.229136/unread





I should be back to it before Christmas.

[JimVonBaden]

Tire day coming up. Versys, GS and Kafe'

[JimVonBaden]

Back on the K.

Cutting, grinding, painting the frame and mild fab.








Continued...

[JimVonBaden]

Engine looks like new compared to the miles.

[JimVonBaden]

Some reassembly. Looking pretty good.

[JimVonBaden]

Just a little mock up touch-up while cleaning and sealing my garage floor.

[JimVonBaden]

Changed direction on the fender. I didn't like the straps, so I filled the holes and made brackets to mount the fender under the mounts.






Finished up the headlight/fairing mount:





Added a stabilizer bracket to the instrument cluster:





Removed the front wheel for paint:





Started prepping for paint:

[JimVonBaden]

Still working the paint prep, between travels.

[JimVonBaden]

Getting close to paint, likely tomorrow if the weather cooperates!

[JimVonBaden]

Paint done. Primer first!





Next color, root beer.









Then Clear:








Lots left to do, but am on the home stretch.

[Laitch]

Helpful setup details in those photos, Jim.

[JimVonBaden]

A little more progress. Trim on the edges, screen on, seat assembled, valves in the rims.






Today I wire all the lights and finish the hoses.

[JimVonBaden]

Wired up the rear lights and installed the inner fender, then the tail light. It is all surprisingly bright.

[JimVonBaden]

Finally off the lift and back on wheels, (what a pain that was doing alone). Mostly mock assembly. Still a lot to do.

[AtLarge]

Well done!   

[JimVonBaden]

A few minor things done. Also finally got the lower radiator hose through the hole in the crank case cover, PITA!


Had to reuse the left side upper radiator hose, the replacement was too short.


Added the new SS brake lines. Not happy with the front, too tight. This is full extension and has a bit of slack, but not as much as I would prefer.


The rear wasn't much better, but will do. These were for a K75C according to the seller, so should have been a better fit.


Much more to go.

[Laitch]

Also finally got the lower radiator hose through the hole in the crank case cover, PITA!

It was never intended to go through the cover on a K75RT. I can imagine the conflict echoing through your shop. Submit! Submit! YOU WILL SUBMIT!  Ok, ok, man. Chill.

[JimVonBaden]

It was never intended to go through the cover on a K75RT. I can imagine the conflict echoing through your shop. Submit! Submit! YOU WILL SUBMIT!  Ok, ok, man. Chill.

For sure. However, if you remove the wire bracket and tilt the radiator back to the original position, it allows it to be done.

[JimVonBaden]

Brakes, side panels, and small bits done.










Runs great:

[JimVonBaden]

Dug it out of the shop and took it for a short ride. Everything works and it rides fine.

A couple of glamor shots then put it away with the others until I get the mirrors and new ignition switch.

[The Mighty Gryphon]

Normally, I don't like cafe conversions.  I consider them hacked up and ruined machines, but your bike seems to get it right.  I really like the fairing which works nicely with the OEM "lunchbox" instruments.  The color scheme of the paint work goes well with the blacked out mechanicals.  Even the seat, which makes my a$$ cringe, looks good with the overall lines of the bike.

I also like that your photos avoid the macho "urban warrior" theme with the graffiti covered dumpster surrounded by garbage and empty beer cans.  That cliche is such a gay joke. (Not that there's anything wrong with that.)

All in all, very nicely done!  You have a true gentleman's cafe bike.  It would go well with a tweed jacket and corduroy slacks.

[JimVonBaden]

Thanks, I have never been a good Cafe Racer fan. They often look contrived and or trash art more than functional. To be fair, I wouldn't want to ride this far. The riding position and handlebars don't work well with my 60 year old back and large tummy. That said, it rides pretty good and has all the stuff to make it legal and a generally all weather bike.

As for the instruments, yeah, I considered a different cluster, but the cost and reduced functionality weren't in the cards for a bike I never really intended to keep.

I has been a fun project though, and I will likely sell it for just enough to break even given the higher miles on it.