Mike4800
Member
My first bike was a 1971 Kawasaki 2-stroke 175cc Enduro I bought new and sold after a couple of years when I got my first new car. Then came marriage, kids, career, and now retirement. A month ago I bought my second bike, "Little Red", a 40 year old non-running wallflower with 6200 miles. I bought it to ride nearby backroads and not to be a period correct restoration. I just want a bike to comfortably and SAFELY cruise and get that wind in my face back. This bike was so forgotten its even dropped out of the CA DMV records system. But I do have a signed title and we go to meet the CHP on Sept 2 for a vehicle inspection to verify VIN and get clearance to reregister it. I hope to have the bike at least running somewhat by then. BTW, I do have a current CA motorcycle license, just rusty.
Here's what I've done so far, with an emphasis on safety:
Bike came with no keys so had new key impressioned so I can operate key switch and open gas tank. Key doesn't work on fork lock or helmet holder. Any suggestions?
Front caliper was seized: No brake fluid left. All had turned to rust and dust. Replaced master cylinder as original was hopelessly pitted. Replaced plugged brake line. Rebuilt caliper and replaced pitted piston and installed new pads. Front brake now works well and bike is MUCH easier to move.
Electrics totally dead: Replaced battery, turn signal flasher and horn. All electrics are working properly now.
Cables: throttle and choke stuck. Lubed and freed up cables. Cleaned and lubed speedo and tach cables.
No spark: Cleaned corrosion out of CDI multi-pin connectors under seat. Replaced spark plugs and boots. Have a reddish thin spark, not the fat blue one I hoped for.
Carbs are plugged: Began cleaning and rebuilding after watching several YouTube videos. Just found the VHT thread on rebuilding the CM400T carbs and am in the process of doing what I can. I rebuilt car carbs as a young man, but these are much more complicated than those. I'm waiting for the WERA 4mm screwdriver so I can try to remove the secondary jets/emulsion tubes which are very stuck. May also need to use the torch trick to get them out. If I can get the carbs working sufficiently to get the bike to start and somewhat run before its CHP date will be a victory. I did install a 4into1.com rebuild kit as I hadn't read the VHT carb thread yet. I suspect carbs will be a work in progress for some time.
Still to do before I can ride, assuming I get the bike running: 1) Gas tank has no rust so need to drain old gas and teardown and clean fuel petcock valve. Lube rusty chain. Air and Oil with filter change. Add fuel line filter. 2) Test ride 5-10 mph around the block to see if bike operates at least near normal. 3) If passes the can I get it to move under its own power test and CHP clears the bike for registration, I'll register the bike and decide if it's worth additional work. 4) If going ahead, replace 40+ year old tires, rear brake shoes, clean and repack front and rear wheel bearings (should I just replace them, are aftermarket sets ~$25-$30 OK to use?), replace the chain, and drain and refill the front fork oil.
If bike is running well, I hope to upgrade lights, especially headlight to LED's.
Always looking for good advice and I'll keep you posted. Thanks.
Here's what I've done so far, with an emphasis on safety:
Bike came with no keys so had new key impressioned so I can operate key switch and open gas tank. Key doesn't work on fork lock or helmet holder. Any suggestions?
Front caliper was seized: No brake fluid left. All had turned to rust and dust. Replaced master cylinder as original was hopelessly pitted. Replaced plugged brake line. Rebuilt caliper and replaced pitted piston and installed new pads. Front brake now works well and bike is MUCH easier to move.
Electrics totally dead: Replaced battery, turn signal flasher and horn. All electrics are working properly now.
Cables: throttle and choke stuck. Lubed and freed up cables. Cleaned and lubed speedo and tach cables.
No spark: Cleaned corrosion out of CDI multi-pin connectors under seat. Replaced spark plugs and boots. Have a reddish thin spark, not the fat blue one I hoped for.
Carbs are plugged: Began cleaning and rebuilding after watching several YouTube videos. Just found the VHT thread on rebuilding the CM400T carbs and am in the process of doing what I can. I rebuilt car carbs as a young man, but these are much more complicated than those. I'm waiting for the WERA 4mm screwdriver so I can try to remove the secondary jets/emulsion tubes which are very stuck. May also need to use the torch trick to get them out. If I can get the carbs working sufficiently to get the bike to start and somewhat run before its CHP date will be a victory. I did install a 4into1.com rebuild kit as I hadn't read the VHT carb thread yet. I suspect carbs will be a work in progress for some time.
Still to do before I can ride, assuming I get the bike running: 1) Gas tank has no rust so need to drain old gas and teardown and clean fuel petcock valve. Lube rusty chain. Air and Oil with filter change. Add fuel line filter. 2) Test ride 5-10 mph around the block to see if bike operates at least near normal. 3) If passes the can I get it to move under its own power test and CHP clears the bike for registration, I'll register the bike and decide if it's worth additional work. 4) If going ahead, replace 40+ year old tires, rear brake shoes, clean and repack front and rear wheel bearings (should I just replace them, are aftermarket sets ~$25-$30 OK to use?), replace the chain, and drain and refill the front fork oil.
If bike is running well, I hope to upgrade lights, especially headlight to LED's.
Always looking for good advice and I'll keep you posted. Thanks.


