Re: Project RTZ

DIY Build Approved

Luck

Re: Project RTZ

thanks for reminding me of my childhood please post a few pics of your aquisition also please post a short description on the present status of the bike

Re: Project RTZ

Started stripping the bike down . It looks like this now


These rusted bolts are giving me a very hard time. Couldn't get WD40 , but got a similar product from 3M . Needless to say it helped a lot .


Petrol tank has a lot of rust on the outside . It looks good on the inside and there are no leaks . Will give it a through clean soon . The body panel near the seat needs replacement though . Front and rear suspensions are gone. The bike has covered slightly in excess of 39000 Km . I will be out looking for some parts and a new cylinder kit .

Re: Project RTZ

before you start stripping the engine get yourself an impact wrench/driver will save you a few head aches in the future

Re: Project RTZ

Will be buying one today

Re: Project RTZ

have you purchased any of the specialised tools like magneto puller , magneto holder, crank splitter etc

Re: Project RTZ

Yes i have bought them the only things remaining are the impact driver and a crankcase splitter. Couldn't find them in shops near my house . My dads gone out today , so he'll try to get them .

Re: Project RTZ

Couldn't do much work on the bike due to a combination of laziness and some other commitments . But now efforts have gathered steam once again . I rebuilt the carburetor the other day . Took everything apart and cleaned it with petrol . This is how everything looked afterwards -



Forgot to take a pic after i assembled it together . I've covered it with masking tape and is stored in a zip-lock cover . Will post pics later . Also removed the cylinder head cylinder and the piston . This is how it looked like -





Haven't managed to get a crank case splitter , so I'll ask a mechanic to come over to my place and split it for me .
@kb100 : I have a doubt . How do you remove the end of the tachometer cable that goes to the crankcase ? I removed the nut and tried to pull it off as suggested in the manual . But its still stuck there and I don't want to do anything to damage it . Any tips ??

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Forgot to mention this in the last post , i found some good videos on Mikuni carburetors for those interested in rebuilding them

http://www.youtube.com/watch?v=wfVQUBO7LjQ

Also stumbled across the Super Tuning Manual for Mikuni's VM series carburetors -> www.mikuni.com/pdf/vmmanual.pdf‎
It explains everything from level zero to how to tune your carburettor .

Re: Project RTZ

afaik its a screw holding the end of the tacho cable, if it is a bit reluctant try spraying some wd 40 and then try ,pray that the end of the tacho cable isnt rusted into the rpm pinion

Re: Project RTZ

Good luck mate. KB100 Parts are hard to get thesedays. I think i have an RR unit for it. Swiss make. I know someone sitting on a NOS KB100 Cylinder kit [Hi-Power make]. But wont come cheap. Let me know if u need.

Re: Project RTZ

I will be starting my KB100 rebuilt soon, its been in the family since 1989 (still have the original invoice with me). Need help in what all tools are must before I start.

Re: Project RTZ

1)A decent socket set with a ratchet preferably with 1/2" drive
2)Impact driver
3)Magnet holder
4)magnet puller
5)crank case splitter
6)crank installer tool (if you cant findn it then take the crank with lhs case to a lathe and have them pres it in for you
7)decent set of c and ring type spanners ,
8)worn out hacksaw bldes, and a 12"long piece of metal rod (a piece of rebar used win concreting will do)
9)a worn out scooter tyre to act as an engine stand (autos tyre will do fine)
10)assorted screwdrives,
11)kerosine, and pain thinner , (for cleaning up carbon from crankcases)
12) last but not least a lot of prayer to your favourite gods

A short ride on the KB100 this Sunday :