Out with the old, in with the new [Part 1] (56k warning)

[McJamweasel]

As most of you will know, I recently discovered a crack in Betty's frame. This left me with 3 basic choices, break her, weld her, or replace the frame. I wouldn't of made much money by breaking her and a weld would of reduced her value and would of needed a full strip down anyway, so the decision was taken to replace the frame.

So, I asked Kawasaki how much for a new one. £575. Plus VAT. Ouch. Luckily, one quick ebay search later and I've got a brand new frame for £400, although it is for the G model, not the J. Still, I've been assured that the only difference is the lack of a steering damper mount. Not a problem - I don't have a steering damper anyway.

So, with a new frame sourced it was finally time to get the job started at the weekend. Keith very kindly came and fetched Betty on the trailer so we could use do the job at his place - complete with huge tool selection.

Now for the job at hand. First things first, strip the bodywork. Not a problem, even the previously annoying crash bungs cam eoff with no problem. Now it was time to start disconnecting wires so that we can have the loom just connected to the engine. Easier said than done - there are quite a few wires. https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5792.jpg

Then it was off with the subframe, now it was staring to look like we were getting somewhere:
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5795.jpg

Next up was to get the wheels/suspension off. As I didn't fancy holding the bike up and we couldn't get the cats to stand still for long enough we bought in some heavy lifting gear. Well, and engine hoist anyway:
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5799.jpg

Just in case you were wondering, the rag near the shock is covering the alarm. It had to go into service mode so was beeping very annoyingly, that was a vain attempt to try and quiet it down a tad. It didn't work.

So, off comes the front assembly, with the wheel in place.
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5805.jpg

The last job for saturday was the rear end removal. This was a bit more of a pain in the arse as we couldn't get the chain off the engine as there was a bracket of some kind in the way. Still, a quick ferkle with the chain guard and it came off the swingarm easy enough. This did leave Betty in rather a sad state though.
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5806.jpg

Sunday morining came, and went, as is usual with me and Keith, then we started again on sunday afternoon. Next step was lifing the frame off the engine. Nothing to it - with the crash bungs out already (they use engine mounts) it was only a case of removing 2 bolts then lifting the frame.
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5808.jpg

So, time to start getting her put back together. Except theres a problem. The 2 frames use slighly different engine mounts, the J has 2 threaded collars, while the G uses smooth ones but through split brackets with pinch bolts. That means the engine isn't going in now. Hey ho. We decide to get the wheels on and just lift the engine into place when we get the mouting kit. So, into place go the head bearings. With the ones in the old frame being 15 miles old the decision is made to try and resuse them. Luckily, they do come out in one piece so can go straight into the new frame.
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5814.jpg

Next up, we bolt the front end back into place, followed by the subframe and some other little brackets that are on the frame. We decide to give it a bit of a clean at this point too, the sunframe is pretty filthy, but nothing that some WD40 and elbow grease won't solve.
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5816.jpg

Time for the swingarm and rear wheel. Keith notices that there isn't a cap over the swingarm bearings and thinks that there should be. Well, neither of us can remember there being one there, and it's certainly not in the pile of bits that have come off. I go and check on the parts list if there should be one there. It turns out that there should. On checking with the swingarm in the frame there is about a 3mm gap, presumably filles by this cap. Hmmm, did we just find the cause of the crack? When the swingarm spindle is done up tight it will pull the frame is just about the right way to cause it. Bugger.

Well, we can't put that on properly without the cap, so theres not much more that can be done. The back end is slotted into place do that it doesn't need to be held up and thats it until I've got the parts I need.

At the moment, Betty looks a bit like this:
https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5820.jpg

https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5817.jpg

https://www.alfa-pages.co.uk/TempPicture/Betty/Img_5797.jpg

I've got a couple of things to sort out, some small bits to get from Kawasaki, I need to get my spare radiator fixed (the one that was on is completely buggered), and theres a small crack in one of the downpipes to get fixed. Then it will be back next week to (hopefully) get here finished off and sold off.

So, once again big thanks go to Keith and Charlotte for the time, help, pop, food and loan ZZR and GPZ.
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BCF: Be yourself, just don't be an arse.

[Dusty]

[McJamweasel]

[zaknafien]

[McJamweasel]

He had a TRX, which G has now. Completely different bike.
____________________
BCF: Be yourself, just don't be an arse.

[paulthewitt]

just a side point. make sure you send docs off to the dvla staing the frame number has changed, etc...

looks like a monster task tho.

Paul

[McJamweasel]

[Zoffo]

Respect! mountain of a job.
So Keith.....I've got this old GPZ1100......
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https://hyperbikes.forumsplace.com/

[distortion]

Nice write up Collin, its coming together !!!!

Saw that engine hoist and laughed me socks off Have heard of Keith's many toys and gadgets but never thought he'd have one of them. Sure its saved a lot of hard graft !!!

Well done Keith & Charlotte - Top banana's !!!

[Ninja]

fantastic - cool read and pictures - I'll keep coming back for updates ...
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James
4 wheels transport the Body ... 2 wheels transport the SOUL

[KevTM]

nice! this is the sort of thing we need to see more of on this site, people and their projects etc..

i'm loving the 2nd pic down, the bike looks cool as hell there lol

[Going2fast]

Great post
Enjoyed reading, big up to Keith and Charlotte
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Passed My Test 15/03/05
BikePics Profile ||| 96' RVF 400 ||| 01' CBR 600 F Sport ||| 2009 Yamaha YZF-R6 Delivered 23/06/09
/-\ndy

[Dom_]

Nice one, and a big thanks to Keith and Charlotte.

Collin, wasn't your zxr i saw in Bikerz a month or so back was it? On the 24/06. (No i didn't remember the date, it's just on a dyno print out off a mates bike )

Dom.

[McJamweasel]

Yes, it was. It was in having the head bearings replaced. Then I took it home and found the crack. :S
____________________
BCF: Be yourself, just don't be an arse.

[Kickstart]

Hi

Basica idea was to strip as littl as possible off. Basically take the subframe off as one complete unit. Should make it far easier to put together.

Plenty of pictures taken to help with any problems reassembling it.

More pics here.

The engine hoist is pretty useful. Used it on a couple of car engine but generally for bikes. Notice the alternative use for ratchet tie down straps.

[Josh|RD125LC]

Saddening to see the bike in that state but at least you know its going to pay off. Looks like you made some good progress.
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Honda MBX50 | Yamaha RD125LC | Suzuki RG125F Lucky Strike | Suzuki GSF600S
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