What are some things I can do myself to revitalize an old motorcycle?

Question

A buddy of mine gave me an old motorcycle of his ('79 kawasaki) that he had in his shed the last couple years (he got from a friend too) that he didnt need (he's got a crotchrocket). Tires were flat and he said he thought the tank has rust or something in it and also that the bike started/ran when he first got it and then stopped. So I figure getting it fixed is cheaper than buying a used one (most likely). So what I want to do is try to refresh, replace, restore some smaller stuff that I can do myself and then if there is a bigger problem, can have a mechanic do that. I will be buying new tires. I will be tomorrow cleaning out the gas tank. Is there anything else smaller i can do to help restore the bike. I guess I should have prefaced this by saying that I got a new battery and the motor turns over (and lights come on) but doesnt start. I only tried it a few times because didnt want the rust contaniments in the gas tank to flow through the cycle.

Answer 1

Save your time and money and get rid of it and get something modern.

Answer 2

Remove the tank, fill it with a couple of pints of kerosene and a few handfuls of pea gravel and shake it until your arms drop off. Then shake it some more. And then shake it again. Clean that lot out and rinse it through with a hose pipe. Then fill it to the brim with cheap cola and let it stand for a few days. Drain that off, rinse the tank out again and allow it to dry out completely before filling it with fuel. Finally fit an in-line fuel filter.

Remove and strip the carbs. They WILL be full of varnishy stinky snotty goop. Getting rid of this will be the biggest problem you encounter and IS the reason why it's not working now. (Trust me on this). Be prepared to buy a set of second hand carbs on ebay.

Change the air filter, blow the spiders out of the air box.

Change the tyres and tubes (if it has them).

Change the oil and oil filter.

Check and adjust the camchain adjustment.

New plugs.

The bike will start-up and run OK at this point, assuming that it was laid up through lack of use, rather than something being broken.

Check the fork tubes for rust pits where the seals travel. Replace the tubes if they're pitted. be prepared to replace the fork seals anyway.

Strip and lube as appropriate the back and front brakes. If it has hydraulic brakes, replace the rubber hoses if they're over 5 years old and the seals in the calipers. Flush the brake fluid even if the seals and hoses are newer than that.

Lube and adjust the chain.

Clean up and check the fusebox connections.

Then ride the thing. It's a great hobby and you get a great deal of satisfaction from "resurrecting the dead". But you may not save a great deal over buying a similar, running second hand bike.

What you will have, which you won't get if you buy a used runner, is that you'll have a bike that you know is in good order, that you know how to fix and that you can trust.

Answer 3

You'll probably need to clean the carbs, however, don't use the high powered soak if you can get by without it. If you do have to, push out the brass needle jet because that stuff will erode it and make it run rich. I know from experience on that deal. If it has the vacume petcock, you 'll probably have to replace that, you can get a new one for around $25 or so, look on ebay. If the tank is rusted very bad, you'll want to seal it inside. If you go that route, remove the petcock and fuel guage if it has one, that sealer isn't good on that stuff. If the plugs are old, put in new ones. I'm sure the fuel system is the briggest problem right now. Run it for a while and if the rings are stuck now, there's a good chance they'll free themselves up. Kawasakis are really tough engines, just give yours clean fuel and oil and it'll probably serve you well.

Answer 4

Pull the spark plugs and shoot a little oil into the cylinder(s) to help protect the rings, replace the plugs, pull the tank and clean it very well, check to see if the carb(s) are gummed up from old fuel, drain and replace the oil and filter, check the brake fluid,lube the cables, verify that the clutch isn't sticking, otherwise when you start it, it could take off on you.replace those tubes and tires, check to make sure the brakes aren't sticking or dragging.

Answer 5

I also agree with the above, and second the motion to obtain a manual. One thing not mentioned, and you may find later is small cracks in the carb boots. Even ones that can't be easily seen by eye will make it run bad. Don't worry about that yet, though. There is no guarantee they are bad. You are on the right track. Get it running first.

Answer 6

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Answer 7

I agree with all the previous answerers. One suggestion I would add however, is to obtain a service manual for your bike. It will assist greatly in these operations.