The Great KR makeover

**Racey Rider** · 11th April 2004, 16:07

Originally Posted by pete376403

Which port was the bridge broken? The bridge prevents the rings from bulging out into the port, so its not really optional, especially if its the exhaust port.

Yes I was aware that might happen. Fine so far, but early days yet.
It was a rear/side port bridge between the lower transfer port and upper KIPS valve exhaust port.

**Racey Rider** · 11th April 2004, 16:16

Yesterday I got the final bits I needed to start a better test of the bike.

Things done to bike:
Steering head bearings - bearings were very notchy, so wanted to replace them. Took the triple clamp off, dropped the fork stem out and found the bearings come apart in pieces.Top race, individual balls and the lower race x2 pressed into the frame took a lot of bashing to get out. they were rather pitted so went off to check price on genuine Kawasaki replacements. Kawasaki sell each item separately. $74.25 for the four bearing races + the balls @$1 each. Must be a cheaper option. Checked the local bearing places. No one had the same type. Still, I’m not paying $100 odd bucks for OEM parts. So I find a bearing thats close, (1mm to big in the centre), Which I pack with a bit of hose clamp. Top bearing race just couldn’t be found, so ended up sanding the pits out and reusing the old one with new balls in it, (But not @$1 each I can tell you!). So steering is sorted. A little tight at the moment, but better that too loose.

Brakes - Callipers were pulled apart and brake pistons cleaned up with sandpaper. The seals were price at $118. PARDON ME!? Yes $118 for 8 little pieces of brake rubber seal stuff from Kawasaki! GET OUTA HERE!

So off I trot to the brake seals shop. “ No, they’re too small. We can’t get anything that small.” Luckily one guy suggested to try Brake fluid resistant O rings. So the local Gasket/seals shop measures and orders some for me.
‘How much Mate”? $4.80
PARDON ME? $4.80. Now That I can handle.
So far they’re working fine. Through some new pads in the front. All good!

Tyres - Front tyre is in good condition. Bridgestone BT-39 ss. Rear a Dunlop K275A bit worn through the centre and flat with 3 tubeless puncture repairs in it. My plan was to change the rubber over to the TT900s I had from last years bike. Already quite worn, but at least I know what grip to expect from them. Don’t know anything about the grip of these current tyres. But after removing the rear tyre from rim, I found the wheel to be 18” and my race rubber wouldn’t fit it.

No money for new tyres, so I had to put a tube in the rear and make do. First tube got recked due to bad tyre leaver technique.

Better luck with number two. The other problem was the tyre wouldn’t sit on the bead right so was quite out of balance. I now realise I should have used soapy water to help it settle into position.

Engine test - I knew the motor was running alright at idle but it was time to test it at full rev’s. Had started it with premix in the tank, but was keen to get the auto oiler working again, (As I had removed the two/ oil that came with it) so changed to straight 91. Doing some slow runs up the road at half rev’s started well until that depressing feeling of the motor jamming up, the back wheel locking up, then freeing, then locking up again. Not goood!

The motor still ran and got me home, but I wasn’t sure what was happening. The next day I donned all my race gear and went to try again, (Hopeing the bike had fixed itself over night,, as you do!).

Sure enough, soon after I picked up the rev’s, and the motor started doing some work, same problem,,, seising up. :disapint: It didn’t feel like the problem was being caused by my broken port problem, so I guessed maybe the oil wasn’t getting through. A check of the oil pump area showed air bubbles in the lines, so that seemed correct. I reattached the premix flow and let the engine run and rev a bit till I was happy the auto oiler was flowing properly. Re-attach the main fuel and go for another run.

Conclusion - I’m happy to say, the bike ran well from then. Slowly built up the rev’s till it was pulling at the red line. No problems.

Man have I learn't alot!

The bike definitely is down on power, (Broken port window, old rings), and yet is running well, (At this stage). If it lasts on race day it will be a good opportunity to practice keeping my corner speed up, (if the tyres are up to it). If it gets through the whole day I’ll feel it’s been quite an accomplishment.

Just goes to show what abuse a two/ can handle.

Thanks for being interested!
Everyone keep an eye out for another barrel for me. 99 KR150.

Will let you know what happens.
Racey

#41 Street stocks.

**Racey Rider** · 20th April 2004, 22:12

Race day ---- Let me see,, where do I start.
How about the end!

Last race of the day, The little KR is singing away as a happy sewing machine should. Halfway through the race, what do I spy out of my little eye???
Dave,, Parked up in the middle of the paddock, with his RS125. :spudwave:

Dave, Dave, Dave!

You know Dave!?

Originally Posted by Dave

If it all turns to shit-package it up and send it too me. Yes i will charge you, but it will be done properly!

That Dave!

The checkered flag falls, and the KR gets a pat on the tank for getting me through the day. As I pull in through the dummy grid, there's Dave telling his Mrs what had gone wrong. So I pull up next to him,,,,,, (Well,,,, It had to be said!),,,, "YOU JUST SEND IT DOWN TO ME DAVE. AT LEAST YOU'LL KNOW IT WILL BE DONE PROPERLY!!!"

The Begining.
A Beatiful day at manfield. My first time on the long track. Saddly my motor wasn't as good as could be, but at least I was out there!
The first couple of pratice session had me concered about a unstable front end. It wanted to weave all over tha place in corners. I tighten the steering head bolt and added air to the front tyre which for the second pratice felt better. I then made a bad mistake. Before race 1 I tighten the steering bearings down hopeing to improve the feel more. unfortunitly this made the problem 100 times worse. As soon as I rode down pit lane, I could feel it so tight I had no control. It was too dangerous to race, so had to miss race 1.

Got it sorted somewhat for race 2. Just as well there was a newbe in my class who gave me someone to race against, as everyone else just took off. Even the smoke had cleared by the time we got to the first turn. But I had fun riding around the outside of this guy in the corners, while he pasted me on the straights.

Good points: The motor lasted all day.

the cheap O rings in the brakes worked great!

Bad points: Steering bearings still need work.
Tyres wouldn't heatup. Might work better when I can push them harder.

Hoping I can get my motor sorted properly before the next round.
If I have time after fixing Dave's bike that is!!

See ya out there!

This has been:
Racey Rider

**bungbung** · 21st April 2004, 08:44

Hey RR, I got tapered roller head bearings for my VTR for $68 from www.schrodoco.co.nz branded "all balls racing".

Give them a try.

**Racey Rider** · 8th January 2005, 19:32

So it's been almost a year since I brought this bike, and finally, I’ve got it sorted.

While down for the boxing day races, I called in to see a chap with another old KR150 that had been crash damaged. Looked like a pile of junk, But to me, it was the much sort after barrell.
Having priced a new barrell at over $900, and having a hard time finding any secondhand one, the only other option was to send my broken port window barrell to Ozz to a Electrosil barrell fixer. $500 + apparently.
(re-sleaving didn’t sound like a good option).

I had seen 1 Kr go on the net for $750. But as this one had high K’s and was looking battered, I told him my best offer was $500. The fact that we couldn’t get it to start on the day helped him accepted the deal. So $500 got me a barrell + lots of other spares.

On getting it home I clean out the carb, dry off the spark plug, and give it the kick. RRrrinnnnng ding ding ding ding ding!
Take it for a quick run. Sweet!

As the kick starter is worn out on the new bike, I decide to removed the barrel and install, with the same piston and new rings onto my old motor base.

Had a good look at the barrell once off. 46000km and it still looked good. Had no tools to measure for wear, so just had to hope that “looked good” would be good enough.

One funny thing I noticed when checking out the bike, Some Wally had put 100psi in the front wheel!

Had "42 psi Max" written on the tyre. Some people have No idea!!

Rear had 60 odd psi.

So have fitted barrell with new rings into my KR. Oiled everything up as it all went in. Then got the Family out to witness the first start up.
After a few kicks to get the fuel through. RRrrinnnnng ding ding ding ding ding!

Well I’ll be a GP mechanic! :spudbooge That sounds just like a new one!

Do a few checks, No water leaks, still plenty of water in the radiator, idling nicely,,
Let’s RIDE!

Donn some basic gear, and head out onto the err, , “test track”.
Give it some warm up time, then go with the “push it hard” run in approach.
Took it for a 30km run, revving hard up to 9000 rpm (redline 10500), then dropping off the rev’s, then making it pull hard again, then off. All good.

Today I gave it a harder workout. Allowing it to rev right up to redline. But since as it is in race bike mode, couldn’t take it for a long run. Motor sounds good, but hasn’t reached the top speed I was looking for yet.

Maybe that’s cause of the contour of the roa... “test track”, or the wind today, or as I was useing oil injection and pre mix at the same time for the first 5 litres, or maybe after only 50km, the rings need to free up a bit more. Hopefully once I get to Manfield I’ll have a better chance to see if the motors
up to race pace.

If I can come up with the money I plan to do the Manfield winter series.

See ya out there.
Racey.

**sAsLEX** · 8th January 2005, 23:13

good shit mate!!! sounds as though your having fun! oh and cheers for taking the CBR up to auckland al those monthd ago!

**Kwaka-Kid** · 9th January 2005, 08:02

YAY RACEY! Good stuff dude!

cant wait to finally catch up with you at the track sometime dude!

**gav** · 9th January 2005, 09:40

Great posts!! Keep up the good work.

Got any photos of the beast?

**Coyote** · 9th January 2005, 10:19

Originally Posted by Racey Rider

If I can come up with the money I plan to do the Manfield winter series.

When does the season start? I hope to enter if I can get some more info on when and how much

**Racey Rider** · 10th January 2005, 20:27

Originally Posted by gav

Great posts!! Keep up the good work.

Got any photos of the beast?

Blue Thunder

http://www.kiwibiker.co.nz/forums/at...achmentid=6388

**Motu** · 10th January 2005, 21:13

You got lottsa legs mate...two sets look atrophied,I don't wanna be rude,but were you born like that?

**Ghost Lemur** · 10th January 2005, 21:30

Looking good RR.

But what's the deal with the kneesliders stuck on the jeans.

I'd say it was a very KK looking piece of kit, but the kneesliders look too pro. *jks*

**Racey Rider** · 11th January 2005, 06:16

Originally Posted by Motu

You got lottsa legs mate...two sets look atrophied,I don't wanna be rude,but were you born like that?

If find if I race with the kids onboard, they can put their feet out and push us through the corners.

Originally Posted by Ghost Lemur

Looking good RR.
But what's the deal with the kneesliders stuck on the jeans.
I'd say it was a very KK looking piece of kit, but the kneesliders look too pro. *jks*

Alright! Let's make it offical.
RR refers to Riff Raff.
Racey refers to Racey.

They'er not actually "kneesliders", but advertiseing hordings. That's why I keep them so new and shiney. That sponsership deal is gunna be rolling in any day now. As for what keep me up in the corners, see above.
Ha! Honda boy would be so lucky!
Racey.