Finally Decided to Start the Donor KB 100 Restoration

[shashikanth]

Hi All,

Finally i decided to start the restoration of my kb 100, i bought this bike only for papers but at last i decided to restore this mechine to decent working condition but the problem is everywhere i see lots of junk bodyline and engene components and long list required parts here i am going to post the progress of my 1989 KB 100 Restoration.Pls Share your Suggestions and guidance

 

[visran]

The handle bar look's like an after market piece, please do replace it with the stock bar, which mechanic have you assigned to work on this bike ?

The spares can be easily sourced from J.C road

 

[alexddas]

The Kawasaki KB 100 the most stable bike at that time.
The shape of the seat looks good.
Do change the seat frame to fiber if it is not.
All the best Bro.

 

[shashikanth]

@ visran: thanks, yes handle bar needs to be changed,mechanic is my friend only..some of the spares i have sourced from Balaji Automobiles, and some of which are missing & unavailable parts i have sourced from shivajinagar.

@alexdas: thanks, seat plates needs to be changed.

 

[visran]

What paint scheme do you have in mind ?

 

[shashikanth]

in my mind i have original paint scheme, but don't know what is the color code of that black with grey shade, any one please find out some info on that.

 

[visran]

What kind of tires are you planning to go for ?

 

[Sam Dinkar]

@shashikanth: Nice bike, there. The KB100 had features that other motorcycles in its time could only dream of. The chassis always begged for more power - it was a beautifully balanced bike. I loved (and still love) it's clean rectangular lines.

Start with the engine and touch the bodywork only after you manage to achieve a reasonable degree of mechanical reliability from this motorcycle.

The original stickering was red and grey on black - on the tank and the side panels.

Do yourself a favour. Dont do anything to the block and the piston if they are in a reasonably good shape. Get a compression test done to know the health of the engine. How many kms has it done?

Ah, the simple joys of a two-stroke:) !!

 

[shashikanth]

@visran: right now i have to make the mechanically perfect after that i will take care of tyres existing tyre will do another 3-4 k easyly.

@sam: since i purchased this recently it doesn't have speedo console so i don't know about the kms the cylinder is gone bad, so i tried for new one but i am unable to source temporarily i have found an standard cylinder and i am going to reset the same, crank also i have bought used. old one roller was broken inside the slot itself the lathe guys told me it cant be removed if we drill it there is chance of rotary disk timing may be go advance.

Parts Sourced Till Now.

ENGENE BEARING KIT
NEEDLE BEARING 2
SKF 6005/6203 2
SKF 6204 4
SKF 6004 2
PACKING KIT 1
OE OIL SEAL KIT 1
OE ORING KIT 1
KICKER PAWL SPRING 1
NEUTRAL PATTI AND SCREW 1
ROTARY VALVE COVER 1
ENGENE SCREW KIT 1
KICKER HALF ASSY 1
CLUTCH NUT WITH WASHER 1
MAGNET NUT WITH WASHER 1
SPROCKET NUT WITH WASHER 1
CLUTCH CABLE 1
THROTTLE CABLE 1
CHOKE CABLE 1
FRONT BRAKE CABLE 1
TACHO CABLE 1
FLOAT NEEDLE 1
SPLINED COLOR GEAR 1
SPLINED COLOR ROLOR 1
ROTARY VALVE COLOR 1

Used Parts
Cylinder
Crank Shaft
ROTARY VALVE DISK
IDLE GEAR
RIGHT REAR FOOT REST Clamp
OIL TANK
BACK FARING
SIDE COVERS L&R
SPEEDO CONSOLE
BEND PIPE
BEND PIPE COLOR
DRUM PLATE REAR
TACHO GEAR
OIL PUMP


List will Be Continued

 

[visran]

Thank's for the info,

Please do try and upload as many pictures as possible at various stages of restoration.

 

[shashikanth]

Finally Got Crankshaft and cylinder reset & re bored , Started hunting for Tacho Gear pinion & Oil Pump Nipple.

 

[shashikanth]

Need Help Guys...

Required Parts

30-12-1010 Gear Meter Screw

30-12-1008 Gear Oil Pump

Anybody Can help me with this need to assemblr the engene.

 

[shashikanth]

got all the gears wheels circlips as used.

Purchased OEM Clutch Plates / Pressure plates, engine rebuild compleated
Now Moving to body line restoration

Purchased New Parts For restoration
Wiring Kit-Minda
Lock set-Minda
Yoke L&R-King
Swing arm axle
Rear wheel axle
Headlamp Stay
HL Stay Bushes
footrest rubber Front & left
Spark plug Bosch
Washers Rubbers Nut Bolts Etc
Air filter Eliment

Parts yet to procure

Battery stand
Tail lamp holder
Indicators
Rectangle Headlight assy
Full Rubber kit

 

[shashikanth]

Hi guys,

here done some work on my kb100 pictures attached your refference

 

[amit1km]

I will not able to contribute to the thread but surly I will keep eye on the thread to see the progress on the restoration process.
Just wishing you good luck and thumbs up.