For my benefit here's the full list of what's been done
As it arrived
Massive box of nuts and bolts all refinished
Powder coated parts
- Wheels
- Swing arm
- Foot pegs and hangers
Every nut and bolt loose or in a bag
none runner
Missing bits of electrics
300 engine
cracked rear engine mount
brakes seized
1 rough looking and intimidating pile of neglected bike
New stuff
Engine carbs and ignition
2 x replate of 250cc barrels
2 x brand new Wiseco pistons kits
1 x fully refurbished crank and new seals
2 x BDK F3 KIPS valves
2 x BDK std valves
1 x BDK KIPS wheels, arms and seals
Venhil Cables
- 2 x KIPS
- 1 x throttle
Genuine Kawasaki
- head & base gaskets
- Carb gaskets
Three bond
Other gaskets are pattern
Carb rubbers
Thermostat temp sensor
Std reeds
Tyga end cans on std exhausts
Clutch (complete)
Zeeltronic PCDI-10VT (map from my other KR1s). Cycles KIPS valves on start up.
Carbs cleaned, new fuel lines and overflow pipes. New vacuum pipe to fuel tap
Piper Cross Air filter
Oil pump ceaned, new oil line from 2T tank to pump
New battery
cut down airbox (to fit alternative shock)
Pipercross (for life) filter
NGK used BR9ECM for heat cycles and initial runs
NGK B9ES for normal use
Carb kit from Cruzin Images 37 Pilot Jet, 135 MJ, std needle clip #4 (2nd leanest) #5 being the one at the top, air screw 1.25 turns out, Float heights 19mm from base of carb to high point of the float. Tickover 1200rpm
Chassis & bodywork
welded rear engine mount
Front & rear calipers refurbished with new seals and pistons
New brake and clutch levers (you can't trust old stuff, it might suddenly snap on you if someone's being propping the bike up against a wall with the weight against the levers)
SBS pads front and rear
Braided lines 2 piece (race) front and single rear line
Torque arm rose joints
New swing arm
Swing arm bushes and seals
Shock linkage seals
Chain slider
Paddock bobbins
Various nuts, bolts rubber grommets and clips
Chain and sprockets
Sprocket locating tab
Rear sprocket bolts
New screen
Dunlop Alpha 10 tyres
R6 rear shock
Original tank and fairing
Full rear mudguard
Original mirrors
Original chain guard
Fluids
Castrol Racing fully synthetic 2T oil
silkolene EP80 gear oil
magnetic gearbox drain plug
100% water for heat cycles
Ready to use antifreeze for normal use
Super unleaded at 40:1 for heat cycles
Super unleaded for normal use
DOT4 brake fluid
Reference data/suppliers
KR1 hard copy manual
KR1s hard copy supplementary manual
Cradley Heath parts list on line
CMS parts list on line
Fastline spares (clutch)
Venhill cables
Goodridge brake lines
Powerhouse/Brakemaster brake caliper services and pads
Cradley Heath genuine Kawasaki parts
BDK Wiseco piston kits
BDK KIPs parts and information
The Tuning Works Zeeltronic ignition PCDI-VT10-KR with plugs
Base settings for Zeeltronic ignition originated from The Tuning Works
The Tuning Works Poten Aptec Ceramic plating spec'd to individual pistons
The Tuning Works refurbished (BDK or Grampian not sure) crank
Courier work by Anyvan (my friend Neil)
Welding by Joseph Percival (Stockport)
MOT at College Motorcycles (Stockport)
Insurance BikeSure (Adrian Flux) multibike policy
Workshop
Everything assembled by me in my living room
Estimated effort around 100 hours, achieved a couple of hours at a time with maybe 3 dedicated full days
Costs, I've enjoyed doing it exactly as I wanted to do it, so who cares.
Rationale
Is it concourse, nope but it has a brand new engine and excellent suspension and brakes. You want to look at a KR1s go buy a picture. You want to enjoy riding one then concentrate on making it stop corner and go like Kawasaki intended
Riding it
Initial break in 3 heat cycles
1st ride gentle run up the bypass. No traffic runnign the engine up to 7k
2nd ride run to the red line to get plug chops
3rd and susequent runs. WOT agin on the bypass to get the jetting right
Suspension, static sag set to my 13st preference, and ridden round the twisty "A" roads to gain feedback and adjust as ncessary