95 K75 Kafe' Racer Project.

[JimVonBaden]

What size are your new handlebars? 7/8" or 22mm?

7/8=22.23mm and the throttle/clutch perches have a tight diameter tolerance so they won't fit on most 7/8" bars.

Have you tried to put the throttle/clutch perches on your new handlebars yet?

This is what I used, no issues with sticking.
https://www.amazon.com/dp/B07MLQJ7SS?psc=1&ref=ppx_yo2ov_dt_b_product_details

They have been on for a while.

[frankenduck]

That's great. I know others who have had 7/8" handlebar issues and I had some 7/8" Renthal bars once that wouldn't accept K perches.

[frankenduck]

It looks like they're from China and are probably 22mm, not 7/8". The title says 7/8" but the description says 22mm and has the weight listed in kg.

[JimVonBaden]

Took the big step and cut off the rear frame, after I welded on the hoop and added reinforcement tabs.












Then put on the tank and seat to see how they play together.








Sharp eyes will note that my welding is not great, but it has improved dramatically. Fortunately none of it is structural.

I'm likeing how it is coming along. Note that the muffler and rear foot peg brackets are not long for this world either.

[JimVonBaden]

Minor work done today. Trimmed the inner fender to match the hoop. It should keep the crap off the rest of the internals. I hate wide open as it limits riding.




Trying to decide where to put the license plate. Note the light will not be here.

[JimVonBaden]

Cut some 1/4" ABS for the seat base and fitted it.




Then trimmed and hammered up the seat support braces:




This allowed the seat to sit flat and be supported.

[JimVonBaden]

Some goodies came in.

[JimVonBaden]

More new goodies came in, side covers, air filter and clutch cable.

Sharp minds will recall my attempt to replicate the side covers. I lost confidence, so ordered some.



Temp mounted the mid-pipe and muffler:


I thought the passenger peg mount was to heavy looking, so:


Then remounted the muffler and mid-pipe:


Better, but now need a mount for the muffler.




This works.

Lastly, still working on where to put the plate.

[frankenduck]

What exhaust is that? Is it made to slip right on the the K75's exhaust header collector?

I guess you haven't run the yet bike but do you have any idea of how loud it is?

Does it clear the  center stand when the center stand is up?

[JimVonBaden]

This muffler:
https://www.amazon.com/dp/B088GV1KFK?psc=1&ref=ppx_yo2ov_dt_b_product_details

This midpipe:
https://www.amazon.com/dp/B07YCNCW25?psc=1&ref=ppx_yo2ov_dt_b_product_details

A bit of trimming and the adapter fit the DB killer and is all snug.

No idea how loud, but I suspect it is not bad.

I need to add a bumpstop for the sidestand, to the muffler clamp. No idea about the centerstand yet. But I am sure it will clear. No doubt it will need a bumpstop too.

[JimVonBaden]

Spent a silly amount of time organizing my garage to get my portable lift free and set up.


Pulled the bike out of the shop and put it on the lift, then shoved the lift, with the bike on it, back into the shop.



Then spent some time vacuuming out the yuck from the airbox, and the rest of the bike.




Sharp eyes may have noticed the destroyed intake pipe. It was frozen on the airbox and required destruction to remove.

[frankenduck]

What the heck is that in the airbox? Alligator eggs?

I'll bet that exhaust weighs a bit less than the factory unit.

I found this mouse nest behind the airbox on a K75RT that I helped a friend bring back to life. It looks like the mouse was stockpiling D-Con poison which makes no sense to me.

[Laitch]

What the heck is that in the airbox? Alligator eggs?

Glands à la sauce aux merde de souris.

[JimVonBaden]

What the heck is that in the airbox? Alligator eggs?

I'll bet that exhaust weighs a bit less than the factory unit.

Acorns.

Weighs about 1/4 as much as stock.

[JimVonBaden]

Got a little work done, not pretty, but the seat is now functionally attached.







Also cut and relocated the lower radiator support to tilt it out of the RT angle to the C angle.

[frankenduck]

Before hooking up and filling the radiator, it's a good time to jump 12V to the radiator fan (violet/yellow & brown connector) to make sure that it still works. Replacing it now would be easier than replacing it later.

[The Mighty Gryphon]

Just curious, but why didn't you at least rinse off the bike before starting to work on it?  Are you building a rat bike?

Personally I hate doing anything on a dirty machine, and the first job with any "new" bike is a good cleaning, followed by detailing every part that I touch for repair or restoration.  For me anyway, working on a clean bike inspires a higher level of craftsmanship.

I guess it's different strokes for different folks.

[JimVonBaden]

Before hooking up and filling the radiator, it's a good time to jump 12V to the radiator fan (violet/yellow & brown connector) to make sure that it still works. Replacing it now would be easier than replacing it later.

Definitely a good idea!

[JimVonBaden]

Just curious, but why didn't you at least rinse off the bike before starting to work on it?  Are you building a rat bike?

Personally I hate doing anything on a dirty machine, and the first job with any "new" bike is a good cleaning, followed by detailing every part that I touch for repair or restoration.  For me anyway, working on a clean bike inspires a higher level of craftsmanship.

I guess it's different strokes for different folks.

I would have, but the day I picked it up it was scorching hot, and once I started removing plastics to get to the parts that needed cleaning I just kept going. In the end I will have to split the bike for the spline lube anyhow, so I will clean it then.

[JimVonBaden]

Received a few parts from Germany, and did a little clean-up.

Parts:


Before:




After:









Not done, but now I don't get dirty just looking at it!

[JimVonBaden]

More or less a non-update. I've continued to strip off a lot of little stuff, refine some stuff, not really picture worthy. I have family visiting, so I needed to clean up the shop (it desperately needed it anyhow), so I will get back on the project next week.

[JimVonBaden]

Found an interesting situation that I only have seen on R-Bikes. The front brake master cylinder appeared locked up, even with the calipers removed. Surely this must mean a bad master cylinder? Nope, the brake line from the Master Cylinder was completely blocked. Once removed, the master cylinder acted normal. Good news for me!

[frankenduck]

Here's what I do for a straight hose from the master to the right caliper:

http://www.kbikeparts.com/classickbikes.com/ckb.tech/0.ckb.tech.files/2vbrakes/2vbrakes.htm

[JimVonBaden]

Finally had time to get back to the project. I wanted to check the seals and splines, so removed the swingarm, then the transmission. Fortunately the splines look good. There is significant corrosion on the clutch components, but the clutch friction plate looks great. I will address the rust, and lube the splines. and reassemble the trans and final drive. The swingarm pivot pins look great!

[JimVonBaden]

Just a bit more.