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Thread: Kawasaki kb100 RTZ rebuild

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    Rusted kb100's Avatar
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    Default Kawasaki kb100 RTZ rebuild

    The re-build of our 1990 model has finally started .
    She was rebuilt 5years ago
    As u can see in these images she is in pretty bad state and the list of parts to be replaced is pretty longto make matters worse original parts are hard to come by thanks to bajaj..
    You guys wont believe the level of abuse that she had undergone in the last 5 years since last rebuildfor starters she ran for 5years without an air filter change
    Order for parts have been placed at the local dealer for parts and have started to trickle down those which are not available will be substituted with similar parts from other models. Tried to hunt for parts some time back in tvm and Chennai found out that parts are available for everything from Yamaha to yezdi but not the kb..until I stumbled onto a shop selling everthing in my city right under my nose

    Finally some thing that I came across in a magazine a few years ago the disc valve technology that Kawasaki uses its 2 stroke bikes was in fact perfected by bridgestone in 60s and wsa transferred to Kawasaki in the 70s as the emission norms were getting tighter and bridge stone wasnt interested in developing 4strokes.the bikes developed by bridge stone were so superior and ahead of its time not to mention its bullet proof reliability tht they were constantly used in racing models like 350cc gtr and gto developed 40hp and had top speeds of 100-110 mph and 0-60 mph time of 6sec figures that were barely matched by the rd 10-15 years later

    P.S sorry for the image qualityit was taken with a phone cam
    Last edited by kb100; 11-21-2010 at 08:46 PM.
    Brijin likes this.

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    Topic Approved.
    ...in search of that perfect world - My Travel Blog :)

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    @KB100 - Appreciate your efforts & glad if you keep posting your regular updates.
    I was & still a die fan of KB100 but for Bajaj. The engine is damn good but the Bajaj saved costs by fibre body on it & the motorcycle rattles after few years.

    Welcome to restoration & my suggestion to you will be to learn everything & do it by yourself. If not get it done right under your supervision by a mech. Do not even go for a tea break when the job is being done.
    Skill is what keeps you on a Motorcycle
    Awareness + Skill is what keeps you out of harm's way
    ATGATT + Awareness + Skill means you might Live To Ride another day

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    Rusted kb100's Avatar
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    thanks argee....btw the rebuild started on 3rd may the whole bike was dis assembled and parts were send out for chroming and painting...should get them by tomorrow and i will be posting a detailed list of parts their part numbers soon as well as the substitutes

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    Rusted kb100's Avatar
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    just bought a new bore kit for the kb

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    Rusted yamdoot's Avatar
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    Quote Originally Posted by kb100 View Post
    just bought a new bore kit for the kb
    WOW thats a grt find! lemme know the list of parts ure looking for.. i'll see if i can get something for you.
    1985 Yamaha RD350 HT
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    great going man.. post some pics of the parts as well!!!!


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    Rusted kb100's Avatar
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    Default Teardown

    The bike was dismantled three weeks ago...there havent been any progress since...got all the shiny bits yesterday after plating and buffing and it costs a lot...got a good no of oem spares from the dealer...more r on the way.....finally got a decent sticker set from the shop mentioned earlier... hopefully we will get the chasis painted this week if the weather permits....and also get the wheels and spokes today alog with a few other odds and ends...posting the pictures also

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    Rusted aargee's Avatar
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    Looks like you've chosen Endurance twin springs. But why? IMO, the old KB suspension was even better, atleast better than Yamaha & Suzuki.

    What did you do on front suspension?

    The bike was dismantled three weeks ago...there havent been any progress since
    @JD - you were 100% right; experience speaks.
    Skill is what keeps you on a Motorcycle
    Awareness + Skill is what keeps you out of harm's way
    ATGATT + Awareness + Skill means you might Live To Ride another day

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    sns rear shock absorbers were chosen because the old ones dont seem to last very long under hard use...dont forget that she is used to carry quintal sacks in the back.. and for the fact that newer ones are hard to find or will have to be substituted with the ones from caliber or 4s
    She ran for almost a year wit busted oil seals on the front forks . that and 20 years of continuous usage has worn out the fork inner and outer tubes.An order for the same has been placed at the dealership and we should be receiving the parts soon

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