Why oh why

[stinkwheel]

Do the Japanese not put a little more thought into the design of their bikes with regard to ease of servicing.

Just been changing the headstock bearings on my KLE. All set and ready with my new bearings, races, a selection of drift punches, hammers, chisels and blowlamp.

Whip the yokes out and set to with a cold chisel to remove the bottom bearing. It was a bit reluctant but a good roasting with the blowlamp got it shifted eventually.

Right. Now to tackle the races in the headstock. Hold on there's no lip! The races are smaller in diameter than the centre tube of the headstock. There is absolutely nothing at all to get a tool onto to drive them out.

They aren't notched so I have left them in, the only way I can see to get them out is to weld a lip round the inside but my welder is broken.

Why oh why couldn't they just make the race a wee bit bigger than the tube it sits in?
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[iCraig]

Don't blame the whole of the Japanese bike industry, just blame Kawasaki!

[tatters]

[McGee]

I get kinda pissed off with the fairings the way they are attached and trying to get them off on some bikes.

R6's are a complete bitch and so are thudercats I heard.
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Its pronounced Jixxer!

[Visitor Q]

Try putting the carb block back on a cbr 600.

All the screws face the same way. Which means the last one is a foot ish away, through an engine.

Riiight
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[McJamweasel]

[Jack_Cheese]

That's clever design to the corporate bosses. If it's easy to service, you'll do it yourself, then the dealers lose out on money, and kawasaki could lose out on parts money.

They deliberately make things awkward, most machines are made only so the pros can take them apart.

Jack
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[stinkwheel]

I just checked in the workshop manual. Changing the headstock bearings in a KLE500 requires a total of EIGHT "special" tools.

By designing the bike with the headstock inside diameter 2mm wider, you wouldn't need them.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Jack_Cheese]

[fast_tzr]

Derbi do it aswell. To get the casing off, one of the bolts is behind the frame, so I ended up having to undo all the engine mounts and move the engine a couple of centimetres to the right just to get one bolt out. Of course, to be able to move the engine, you had to remove the exhaust. From what i remember I ended up stripping about half the bike eventually!
And the worst thing is, it still needs putting back together again....

[element]

scooters are even worse. My speedfight is something else. To get to anything you have to take half the bike apart. To change the brake pads on the rear wheel you have to remove the exhaust (eventually found a way of avoiding that), remove the wheel, remove the caliper...

All the panels bolt to each other in ways ways that require more and more panels to be removed. Horrible to work on. I wanted a sports bike till I realised how difficult they can be aswell... I think my next bike after my DT will be a supermoto
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[Itchy]

didn't somebody once say? ,

a bike ain't a proper bike unless you can put you fist through it , that said though they look OK , classics would probably be more of a handful maintenance wise.
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