10 months and I am back on this bike :) sohuld have finished it off last year!

anyway.. the fourth lock and the last one - opens with the recut keys! I have to chop this from the original fuel tank (pic soon) and will fit it into spare tank later... then I need to sort the exhausts, bleed brakes, add cooling, and fire her up :)

Time for rebuild...

Leaving rear caliper off until chain finally made 'endless'

A good quality but Cheap (ebay) o-ring chain and sprocket kit. Regina chain, and JT cogs. For a GPX 600 (15 and 39 teeth) but fits perfectly. Have a JT 13 tooth on the front so overall ratio is down from 3.2:1 to 3:1.. should be close enough and will allow for lower revs at high speed.

Dont even mention airbox rubbers to me !.....
how to waste 2 hours.. damn Mr kawasaki.

Frame bolt heads and threads wire brushed

Linkage loosely back together.. waiting to get chain made 'endless' before final build here...

Note GPZ 500 shock..

Some Paint. New unitrak linkage, headbearings

Speedo linkage and cable, degreased, and very clean internally..

Swinger - after silver, before Laquer

Engine scrubs up quite well.. could have put more time in, but time has all but ran out.. Casing looks ok, as does rocker cover... Casing bolt snapped off near front, but managed to get broken part out no problem, blow torch and WD40 and patience...

Calipers rebuilt, pistons were good, a coat of black....

Some alloys bits

New linakge ;)

Frame given black gloss hamerite (ok on direct metal)

New tapers

Disc came up ok..

Begin the cleanup...

Carbs back together, no signs of wear on needles, all look ok




Swinger taking shape...

Big headache, still not sure what to do, tanks are like hens teeth in UK :(

Note the worst holes, lower left of this pic, big and low down :(

Lock stuck too... can't even open it :(

Frame ready for paint, the worst of the surface rust removed..

Rocker cover and coolant pipe degreased, wire-brushed..

Center stand given a quick brushing.. not wasting too much time on this..

Main body work etc.. generally good. Will repaint front mudgaurd. RH sidepanel is very soft from Fuel contamination. Fairing upper and lower generally good.

A few parts

Will clean with rubber restorer firstly.. Tyre has good tread and no sign of cracking/damage. Front tyre U/S, found a part woen for it..

Got one of these on ebay for £0.99 ! new from MR kawasaki, they are around £40-60 I think..



Pretty normal condition for a 20,000 mile swinger


Years of leaking petrol has taken paint of LH casing

Rusty but just about within service limits....

Begin stripdown

Looks like bird seed in the Battery box...

Shelves filling up with bits (most have been through the parts washer by now)

Ready to remove swinger etc.. So much easier working at this height, so much easier than a car..

Note RH sidepanel corner sticking up from petrol contamination...

Transport bike home

Ready for complete stripdown...

Picked it up in my trusty old citroen (WVO).. only just fitted....

It took 3 of us to shove it in there, managed to remove it alone with the help of the old crane..