LKC73's Z250 Cafe Racer project

[LKC73]

Hey fellas, I know its not a street fighter, and not the big bore bikes you guys normally like to see up in here, but I got this bike of a council clean up so the price was right.
I got a free Kawa Z 250c 1980 model which im converting into a little cafe racer style bike.
I got it home last thursday, and started on it almost straight away.
The first thing I did was to check that the motor wasnt stuck or buggered. But seeing that the battery was buggered, I could only hand crank it from the stata bolt. It was all clear with decent compression.
http://www.asfphotos.com/upload/1242445820.jpg


http://www.asfphotos.com/upload/1242397399.jpg

[LKC73]

The next day I managed to strip the bike down and with a battery charger I check all eletricals to see if they works, 2 tumbs up there also!
I also got a cheap arss battery from supercheap and the little bugger cranked over with ease! I still need to put fuel in it to fire it up and get it running though.
http://www.asfphotos.com/upload/1242493420.jpg


http://www.asfphotos.com/upload/1242447106.jpg

[LKC73]

Then last weekend I started modding a little, first thing I thought of was to flip the bars over on the risers to see how they went, and I think the result isnt to bad looking.
http://www.asfphotos.com/upload/1242467578.jpg


http://www.asfphotos.com/upload/1242474537.jpg


Also, you maybe able to see it, but Ive dropped the guage bracket to the underside of its mounts so the guages sit almost on top of the headlight, this will keep the guages below the risers which is around a 1 & 1/2 inch lower then standard. I test fitted to see if both speedo & tacho cables cleared, and they did.

[LKC73]

As it sits now, Ive taken the seat apart, chopped the foam 2 inchs down, and the pillion section off for the single cafe section. Ive yet to cut and weld the steel base plate for the seat, and that will happen over the weekend.
http://www.asfphotos.com/upload/1242491332.jpg


http://www.asfphotos.com/upload/1242480150.jpg

I also placed the tank on the bike to get an idea of how it is shapeing up, and I think its starting to look more cafe now, even if its still in bits. Oh and I removed that huge rear fender. That wont be going back on.

One thing I have learnt from you fellas, is to construct the bike, then pull it down & clean it all up and paint, and re-construct. Ive got a 3 month plan for the little bike, coz I cant do much else with my time.

Future plans are also to get the 84 front end, as it has disc brakes. Build the rear cowl, and cut the rear pegs off, weld on some brackets for rearsets, get the rearsets on and the tidy it all up. Not sure on colour yet, but thats the last thing im think about right now. I'll keep this up to date though, as it is my first bike build ever.

[Tomanyprojex]

He he, looks like fun. On ya go matey..

[Warmaster]

You've gotta start somewhere mate.

Looks like fun.

[Hillsy]

Did you buy it from the Council or did you pick it up off the side of the road??

[Iceman]

That's cool, I'm building a chopper from an 81 model Z250

http://www.streetfighters.com.au/forum/topic.asp?TOPIC_ID=13027

[Fight_fan]

Thats sick man! I wanna build a cafe racer too!

[LKC73]

quote:Originally posted by Hillsy

Did you buy it from the Council or did you pick it up off the side of the road??


Mate, I picked it up from the side of the road where it was laying in a big pile of rubbish. I got in contact with the fella that was tossing it out, and he said take it.

Oh and I got some fuel yesterday, and started it up, took some time but it did fire and run. It has no major sounds but the carbi needs a rebuild.

So today I went to town on it, removed the swing arm, cut the rear footpegs off, pulled all wireing out, removed the front pegs, and removed the engine.
I found one engine mount had cracked, so I welded it back in place, and all peachy now. Next thing Im on is pulling the forks off. Im thinking of getting the frame chemacilly cleaned, seeing as Ive go this far with it.
http://www.asfphotos.com/upload/1242573139.jpg


http://www.asfphotos.com/upload/1242631404.jpg


http://www.asfphotos.com/upload/1242597910.jpg


http://www.asfphotos.com/upload/1242558049.jpg

[LKC73]

Well, with this craptastic weather we been having in on the east coast, Ive got some more work done to the little bugger.

http://www.asfphotos.com/upload/1243177322.jpg

Frame is completely stripped down for sandblasters on Monday

http://www.asfphotos.com/upload/1243110551.jpg

Cleaned and polished the front guard, just to see how it turned out.

http://www.asfphotos.com/upload/1243088907.jpg

Painted the tripple clamps

http://www.asfphotos.com/upload/1243145664.jpg

Finished cleaning the carby up for refitting.

http://www.asfphotos.com/upload/1243165877.jpg

Got the tyres removed and will be cleaning wheels for polish & paint.

[LKC73]

Done some more work today, one of which I dont have pictures coz it was just alot of cleaning and getting the frame ready for sand blasting still.

I did clean and polish the risers, cleaned the brakes front & rear, found the sprocket carrier was bare alloy, so painted that in the same finish I plan on doing the wheels in.

Here is todays work. I know its not much to look at right now, but it will look ok when its complete.

http://www.asfphotos.com/upload/1243219340.jpg


http://www.asfphotos.com/upload/1243196426.jpg


http://www.asfphotos.com/upload/1243175062.jpg


http://www.asfphotos.com/upload/1243251816.jpg

[BANDITROD]

fucking hell mate slow down for fucks sake let everyone else catch up lol..... looking good by the way

[sen]

Nice going mate.. can't wait to see this finished.. definitely gotta build me a cafe racer one day, but with my size it'll need to be something bigger than a two fiddy ;)

[LKC73]

quote:Originally posted by sen

but with my size it'll need to be something bigger than a two fiddy ;)

Mate, there really wasnt a choice in the matter, when you get something for nothing, you dont knock it back [:p]

I would buy a project soon enough, but for cutting my teeth on project bikes, this is perfect.
Frame has returned from sand blasting also, so rearsets will be mounted next, pics to come soon.

[wackyrider]

This is looking awesome mate

[Weaselman]

MORE

[LKC73]

Ive just done 1/2 days work on the old girl today. Didnt feel the best after a big night to get the early start I planned to. But I did manage to get the rear sets on the frame. After I picked the frame up from the sand blasters on Friday.

I got some GSXR rear sets free, and 10mm plate which I tapped out for the mounting bolts. Then welded the 10mm plates to the frame. and there we go, rear sets on. Now i just have to make a gear shifter and brake lever for them both.

http://www.asfphotos.com/upload/1243775721.jpg


http://www.asfphotos.com/upload/1243749829.jpg


http://www.asfphotos.com/upload/1243706134.jpg


http://www.asfphotos.com/upload/1243687714.jpg


http://www.asfphotos.com/upload/1243696477.jpg

[CBRRRT]

Very impressed with your work matey, very well done so far fella.

See that casting line along the middle of you foot break lever? If you file it off and then sand the surface with 120 grit aluminium oxide, then finer and finer wet and dry, and attack it with solvo autosol, it'll polish up right nice.

I did it to my Blade before its transformation.

http://www.asfphotos.com/upload/1244168059.jpg


http://www.asfphotos.com/upload/1244230009.jpg

[latheboy]

Shit hot Luke, I got 2 or 3 bikes to finish before i can start my cafe racer, but i think its one of those things everyone should hace

[LKC73]

Ive done a little more to the old girl this weekend. Finally got my tail section in the post. I fitted it up, and it needed a little modding up to look the way I wanted it to.

I also started relocating some of the electrics that sit next to the battery. I want to leave that area a bit open to look very miniumal. Pic's are as titled, and I just have to do some fibre glass work on the tail section now.
Once I have all the wireing sorted out, its then time to strip the frame and paint it. I will move onto the body work then.

http://www.asfphotos.com/upload/1244437754.jpg


http://www.asfphotos.com/upload/1244424789.jpg


http://www.asfphotos.com/upload/1244411457.jpg


http://www.asfphotos.com/upload/1244408230.jpg

[LKC73]

quote:Originally posted by CBRRRT

See that casting line along the middle of you foot break lever?


Cheers CBRRRT, but I wont be useing that actual lever, I will be making my own to suit the drum rear link rod. But I do plan to polish the rear sets then self. Ive done a few things for mates in polishing swing arms, frames, and other bike gear.

Thanks latheboy, this is my first complete bike rebuild Ive done, and will take what I have learnt from this and hopfully the next bike will be a proper fighter!

[JackTar]

I am watching this with a great deal of interest, good build thread mate keep it up I want to see more.

[Jay_G]

cannot tell from the photos, but if you haven't got any primer on the frame get some etch primer on there stat.. before the surface rust kicks in.

[LKC73]

quote:Originally posted by Jay_G

cannot tell from the photos, but if you haven't got any primer on the frame get some etch primer on there stat.. before the surface rust kicks in.


Jay, thanks mate, already done that today. I wanted to finish off welding bits and shits on before I put paint down, primer or any other. Ive given it a coat of etch primer today, and giving it a day or 2 before I start the colour.

[HueyonaBlade]

Extremely neat mate those GSXR rearsets look factory .[:p]

[Lewis Moto]

Watching this.
Coming along well.
I have a penchant for old Kawasaki's, particularly small capacity Kawasaki's. I am interested to see your build and to see how you go getting it passed for rego. Have you got any foreseeable problems with ADR regs or are you going to wing it and see what comes up?
I have a couple in the garage that have been built for the track but I am curious to see how much more effort would be required to have them running on the road as well - double the fun!

[LKC73]

quote:Originally posted by Aido

Have you got any foreseeable problems with ADR regs or are you going to wing it and see what comes up?

The rearsets my cause a drama as its being a chassis mod. The other things like fenders, lights, chain guard will all be removeable once a bluey is complete. Ive been talking closely to a bike shop on whats required for the blue slip.
Ive also been told of a few <s>easy</s> type place's for Moto blue slips.[8D]

[LKC73]

Weekend update; Painted frame through the week, and let it dry for a few days before the weekend. Started putting some gear back on it. I also cleaned the rear shocks up a bit, they didnt come up to bad at all for 30 year old units.

I also started the fuel tank, rubbed it back to primer and then filled some dents and primed it with some sanding primer high fill shit layin about the garage.

http://www.asfphotos.com/upload/1245567382.jpg


http://www.asfphotos.com/upload/1245614891.jpg


http://www.asfphotos.com/upload/1245652076.jpg


http://www.asfphotos.com/upload/1245636440.jpg

[80s freak]

Looking fantastic, a mates doing a cb250rs cafe job. As for your rear shocks, you will probably find bugger all dampening left in them. If you want something that looks decent works well and won't smash the budget, have a look at some "YSS" items. any bike shop can get them from Cykel products. I run a set on my 1100 and am very happy with them.

[LKC73]

Yet another update;

Spent the last 2 days doing some fibreglass work to the seat unit, making a seat mold, and a little under tray to slow the water down on wet days going into the electrics. I then primered the seat unit & tank. 80's Freak, cheers, I'll look them shocks up, but as for now, they will do until I put it on the road.

http://www.asfphotos.com/upload/1245718773.jpg


http://www.asfphotos.com/upload/1245753008.jpg


http://www.asfphotos.com/upload/1245671442.jpg


http://www.asfphotos.com/upload/1245683625.jpg


http://www.asfphotos.com/upload/1245694859.jpg

[LKC73]

Just another update! After a shit load of prep work and a lot of sanding, primer filler, sanding again, I finally got the tank and seat unit to a stage where I can put some colour onto it.

Here is the base coats of black on it, then placed on to see what the colour contrast will look like. I'll be doing some more paint hopefully on the weekend.

http://www.asfphotos.com/upload/1246482659.jpg


http://www.asfphotos.com/upload/1246481038.jpg


http://www.asfphotos.com/upload/1246502661.jpg

[Harry]

Nice work mate :)

[sen]

Damn.. that's shaping up mate.. can't wait to see it finished.. making me want to build a cafe racer more than ever.. passing Deus every morning doesn't help either!

[Harry]

buid one mate,dont buy a fuckin deus.....the price of em is bullshit!...................[}:)]

[LKC73]

quote:Originally posted by Harry

buid one mate,dont buy a fuckin deus.....the price of em is bullshit!...................[}:)]


Your right there Harry, and there all new bikes that you pay double for!

[sen]

Nah don't worry i'd never buy a Deus, I just meant that seeing all the cafe racers out front there keeps teasing me to build my own. I have different taste to their bikes anyway.

[80s freak]

Looking great! Keep on rocking.

[thejester650]

the frame looks sweet! coming along great man.

[gixkat]

good stuff mate, gotta love the cafe's, are you gonna bring another color into that tin work?

[LKC73]

quote:Originally posted by gixkat

good stuff mate, gotta love the cafe's, are you gonna bring another color into that tin work?


Yeah, getting some pin strip green to match the frame, maybe shadow it with a bit of silver in keeping with whats chrome & alloy but that will be just about it. I want to keep it simple.

Ive done a bit more work, but without pictures. all the wireing is now done, headlight back on, guages and motor is installed. Ive located some forks for it, but the place isnt open until the 21st of the month, so that will have to wait. Then its tyres, chain & sprockets and back on the ground.

[LKC73]

quote:Originally posted by gixkat

good stuff mate, gotta love the cafe's, are you gonna bring another color into that tin work?


Added some colour to the tins yesterday, gave them a light rub back this morning but ran out of paint thinners for the clear coat, so I'll be getting into that another day.
Just thought it would break up the black nicely as it is.

http://www.asfphotos.com/upload/1248009487.jpg


http://www.asfphotos.com/upload/1248047659.jpg

[miniman1]

Lookin real good mate!! I scored myself a cafe project the other day... Just gota arrange to pick it up so i can get stuck into it.

[sen]

Damn, that looks awesome.. The green stripework really suits it. Love the bars too, had them on my GS500..

[Gitzy]

That things goin to look great mate..

[80s freak]

more inspiration for others, looking great!

[sen]

How's progress going?

Just picked up a CD250U last night to start a little racer project for my housemate and gf to share through their learners/P's..

[LKC73]

Just thought I would update this thread. The bike is almost together now, just got to get some tyres fitted, the seat trimmed up and oil & filters and away she go's :D
http://www.asfphotos.com/upload/1250539349.jpg


http://www.asfphotos.com/upload/1250590519.jpg


http://www.asfphotos.com/upload/1250586535.jpg


Tail light and blinkers are now on, all electrics are done bar the coil lead. Its starting to take some sort of shape now.

[80s freak]

Looks the dogs bollocks mate! Have you thought about trimming the front guard?

[TurboKat]

This bike is looking fantastic, best budget build I've seen in a long time. [^]
Also really digging the black/green contrast, simple & effective - good work.
+1 with Geoff on trimming the front guard a <s>bit</s> lot & if it was mine, I'd be looking for a set of spoked wheels to set it off. [:p]

[LKC73]

TurboKat, I would look for the spoked wheels, and did have this thought but I also like to keep it at a budget like you have said. So far this bike has cost me $700 big ones and that includes new tyres which have yet to arrive and be put on.
80's Freak, as for the front guard, Im waiting on the tyres to see how she looks. There is a rear guard also, but that will only be put on for the blue slip (if i ever get one)...
Ive got more thinners now, so the final clear coats will be a go this weekend.

[Surt]

quote:Originally posted by LKC73


http://www.asfphotos.com/upload/1250590519.jpg






ha! another 'railroad' bike! ;)

nice build mate, luv the cafe racers, urs gotta be an awesome one! classics forever! [8D]
ps aint u gonna change the central stand with a side stand?

[LKC73]

Alright lads, its time for a small update, and new piccys! The new tyres are on, and everything is about ready to go, just needs a few more little things, but Track day next weekend, and rego the following week have slowed things down on the project a bit.


http://www.asfphotos.com/upload/1252227229.jpg


http://www.asfphotos.com/upload/1252299866.jpg


http://www.asfphotos.com/upload/1252298588.jpg

[Fight_fan]

Lookin VERY tidy mate! I like it!

[Tarzan]

green frame sticks out like dogs balls all kwaka nice. If your looking for badges theres a bloke in aus who does repros tonnes of old ones

[LKC73]

Hey Lads, Ive taken way to long to let you know Ive finished this bike.
Ive already moved onto the next project, which is a trackie to thrash around on.

Heres the finished product.
http://www.asfphotos.com/upload/1257944215.jpg


http://www.asfphotos.com/upload/1257928653.jpg


http://www.asfphotos.com/upload/1257860215.jpg


http://www.asfphotos.com/upload/1257914412.jpg


Have a laugh at the name in the seat, it was done as a bet, but it kind of grows on you seeing how small this bike actually is [:p]
Just needs rego now (if I stop spending money on the track bike).

[80s freak]

Looks good mate well done.

[pt]

Looks alright.



VERY tidy:)

[Large]

Deus ex machina would want $20000 for that little ripper.

[BANDITROD]

^^^^^^^^^^^^^^aint that the truth ...... what a little ripper mate well done

[CBRRRT]

Very tidy mate, nice job well done!

[HOS]

LOVE IT !!!!

Pleasure to see mate ... taa !