Kawasaki Sportsbike Riders Club - Australia - Online Forum

The time has come to bite the bullet and get this wonderful old race/road bike back on the road. I don't know how long it's going to take, how difficult it's going to be or how expensive it's going to be, but, if I don't make a start, it will never get finished. For those who don't normally follow this forum, here is the story of the bike.

http://www.halfofmylife.com/races-racers/great-races/the-shadowfax-story/

After moving down here to Wollongong, the bike was covered in several tarps and stored behind my shed until I could find room in the garage for it. Unfortunately, that never happened, and the bike has suffered at the hands of the coastal humidity, as you can see. Since these photos were taken at fairly high resolution to help me with details and re-assembly, I won't embed them in the thread, but rather just provide links to them as I go. I hope this is suitable.

http://i.imgur.com/Wl9no.jpg

The front brakes were jammed on so the first step was to remove the calipers. Surprisingly, most of the bolts I have undone so far have come open really easily. I hope that this continues.

I then walked around the bike, taking lots of pictures for reference as indicated above. Some of the details are immediately interesting. The drilled front disks, for example. Also the custom-made triple clamps and the solid fork brace.

http://i.imgur.com/nSod7.jpg

http://i.imgur.com/3LD0a.jpg

The frame was substantially braced and strengthened around the steering head.

http://i.imgur.com/jUZ6K.jpg

Period Marzocchi shocks

http://i.imgur.com/SfdZB.jpg

The box-section swingarm hasn't fared well.

http://i.imgur.com/SBLV0.jpg

No rear brake at all at the moment. The bike raced with a drum brake on the rear but I have a disk and associated hardware amongst the spares.

http://i.imgur.com/oXnNk.jpg

Note the "budget" paddock stand the guys fabricated from a centrestand! OEM, circa 1981.

http://i.imgur.com/TF1ho.jpg

Another shot of the heavily modified steering head and also the period steering damper.

http://i.imgur.com/zruaL.jpg

Lockhart oil cooler

http://i.imgur.com/8pLAf.jpg

Battery box and associated wiring harness look to pretty shot, will probably see if I can install a complete new loom.

http://i.imgur.com/EDeuC.jpg

So, that's what it looks like. I have already lined up someone to rebuild the engine, just back to "as was" (It is a Moriwaki 1105) and I need to now start stripping the frame, photographing and labelling.

Now, as regards the rust on the frame. Do I get it sand blasted or chemical dipped? Also, can anyone recommend someone who can redo the forks for me?

That's all for now. It's going to be fun. The aim is to rebuild using as much of the original bike as possible and to restore to "as is" condition in 1981. Any suggestions/criticisms/help/etc that you guys can provide will be gratefully received.

fezzick wrote:
I have already lined up someone to rebuild the engine, just back to "as was" (It is a Moriwaki 1105)

If that falls through, Rick Miller is still on the tools here in Canberra.

dub wrote:

fezzick wrote:
I have already lined up someone to rebuild the engine, just back to "as was" (It is a Moriwaki 1105)

If that falls through, Rick Miller is still on the tools here in Canberra.

Rick was my first choice. He's been servicing my bikes for over 20 years. But he's not doing engines any more since he had the CTS problems with his wrist. Suffice it to say that another Canberra mechanic is going to do the engine.

You just want to get the forks you have sorted Phil? Glenn Allerton has just opened a business doing suspension He worked at Shock Treatment for years so that may be an option.

Another option in Sydney would always be Glenn Willing, if you are OK with freighting you could also try Stu Winton from SW Racing or Steve Mudford from Technical Partners - both of them are in Vic though.

If you have a few $$ you may even want to try Frank Pons or Terry Hay.

Let me know if you need any contact numbers etc.

Still got the VFR?

Phil wrote:You just want to get the forks you have sorted Phil? Glenn Allerton has just opened a business doing suspension He worked at Shock Treatment for years so that may be an option.

Another option in Sydney would always be Glenn Willing, if you are OK with freighting you could also try Stu Winton from SW Racing or Steve Mudford from Technical Partners - both of them are in Vic though.

If you have a few $$ you may even want to try Frank Pons or Terry Hay.

Let me know if you need any contact numbers etc.

Still got the VFR?

Thanks, mate, I'll keep those contacts in mind. No have the VFR any more. After the accident last October I've decided not to ride any more. I'm still recuperating and not back at work yet. The Kaw is my only bike now.

fezzick wrote:

Phil wrote:You just want to get the forks you have sorted Phil? Glenn Allerton has just opened a business doing suspension He worked at Shock Treatment for years so that may be an option.

Another option in Sydney would always be Glenn Willing, if you are OK with freighting you could also try Stu Winton from SW Racing or Steve Mudford from Technical Partners - both of them are in Vic though.

If you have a few $$ you may even want to try Frank Pons or Terry Hay.

Let me know if you need any contact numbers etc.

Still got the VFR?

Thanks, mate, I'll keep those contacts in mind. No have the VFR any more. After the accident last October I've decided not to ride any more. I'm still recuperating and not back at work yet. The Kaw is my only bike now.

Every cloud has a silver lining, bad news your not riding anymore as I know how much you love it - but at least you only have a Kawasaki now You still got my number from when we did the 6 hour?

Well if your looking for a steady & machanicly friendly rider, my hand is up Phil..

s man wrote:....Well if your looking for a steady & machanicly friendly rider, my had is up Phil.. .....

the queue starts right behind *me* !!

Phil wrote:

fezzick wrote:

Phil wrote:You just want to get the forks you have sorted Phil? Glenn Allerton has just opened a business doing suspension He worked at Shock Treatment for years so that may be an option.

Another option in Sydney would always be Glenn Willing, if you are OK with freighting you could also try Stu Winton from SW Racing or Steve Mudford from Technical Partners - both of them are in Vic though.

If you have a few $$ you may even want to try Frank Pons or Terry Hay.

Let me know if you need any contact numbers etc.

Still got the VFR?

Thanks, mate, I'll keep those contacts in mind. No have the VFR any more. After the accident last October I've decided not to ride any more. I'm still recuperating and not back at work yet. The Kaw is my only bike now.

Every cloud has a silver lining, bad news your not riding anymore as I know how much you love it - but at least you only have a Kawasaki now You still got my number from when we did the 6 hour?

No, mate, I don't. You wanna PM it to me?

So, here's the deal. Yesterday I pulled the wiring harness out and it looks pretty dodgy. My feeling is that, if I'm going to do the job properly, I should replace the whole harness. What do people think?

do it properly the first time and you wont have to do it later

h.b.bear wrote:do it properly the first time and you wont have to do it later

My thoughts, too! Thanks.

Gosling1 wrote:

s man wrote:....Well if your looking for a steady & machanicly friendly rider, my had is up Phil.. .....

the queue starts right behind *me* !!

Back off Gos, I was here first! lol

OK, more progress (pics to follow). This morning I stripped out the wiring harness including switchgear, coils and plug leads. I removed the oil cooler and the front indicators (were attached to the same bracket). I removed the master cylinder and calipers (in one unit at this stage just to keep things together) and disassembled and removed the front forks and front wheel (as a unit again), clip-ons (Maguras), steering damper, top and bottom triple clamps and the steering stem. Pleased to be making headway even though it's slow.

Frame and forks now separated

http://i.imgur.com/FrnLq.jpg

http://i.imgur.com/s7zXr.jpg

Brake assembly taken off as a unit.

http://i.imgur.com/nIWiz.jpg

Assorted bits; Magura levers, L/H switch block, clutch lever and assembly, steering damper, custom-made triple clamps with steering stem.

http://i.imgur.com/iV9oG.jpg