all makes ...... okay kawasaki

[big mick 1981]

Up realy late one night mucking arround on ebay looking at bikes but the prices were to much to pay in one hit so thought about buying something to rebuild as the summer was coming to an end anyway. To be honest I don't know what came over me but it was probably the fact that it was a straight frame, hpi and accident damage clear for 40 Quid that won me over


So blasted the frame, cold galvanised it then painted it gloss black . That was alway the Achilles heel of the er5, the paint finish was terrible rusting at the sight of moisture.

Managed to get a load of bits from a guy breaking a er5 with a busted engine for in total 140 quid . Tank, seat,failings,full lock set, yokes, handle bar,switch gear, radiator, fan, rear shocks, undertray, mudguard, expansion tank and various hoses

Ebay also got some scores front wheel with good tyre ....... 5 quid , rear wheel with matching tyre 60 quid a few wee bits and bobs under a tenner which were all blasted and painted gloss black

Trying to get a decent set of forks was a blimming nightmare, bought one set with fork leg damage and another with stanchion damage and built one good set . Before rebuilding them I stripped all the paint from the fork legs and gave them a good polish, also done the fork hangers at the same time.

All bearings are new , all seals are new , nowt will be going back on unless it's new or rebuilt to be as New

Finaly got her back on two wheels last night but will be stripping both wheels off again when I can afford rear sprocket and front disk . The rear shocks that are on are only a stop gap till I can get a new set .


This probably won't see the road for another year yet as bigger money to be saved up for the engine , carbs then New gasket and seals kits to rebuild them

[big mick 1981]

This is what my 40 quid got me


A little bit of a squeeze


Coat of cold zinc galv


Final coat of gloss black

[big mick 1981]

Few second hand parts got the shot blast and gloss black treatment

Swing arm






Yokes



Rear brake plate



Hub




Wheels ( only the very late model er5s came with black wheels)




Forgot to take a before pic of the front wheel but it was silver aswell

[big mick 1981]

Got my self a bench grinder and some polishing pads

Fork legs





Hangers ( these were done by hand before I got the machine lol took ages )




Swing arm sliders (quite bad pitting but looks not to bad)



Brake plate brace bar

[big mick 1981]

Bought all new bearings,fasteners, seals then put together what I have

[big mick 1981]

Run out of metal to play with so my attention turned to my broken rear plastic fairing . Never tried plastic repair before but it's free try lol a bit from a aerosol lid and a solder iron has seemed to have worked

[big mick 1981]

Not much happening lately but couple of jobs







The engine supposedly ran good in last bike ......... £ 40 worth a punt I thought

[big mick 1981]

Another bargin by at upullit, 3 mk5 golf abs sensors, zzr 600 fan shroud and fan in as new condition plus a horn ........ £5 lol

The er5 fan was to gubbed to try clean up so adapted the er5 shroud mounts to fit then my mate welded them onto the zzr shroud





Extra cooling for under a fiver, result

The shroud has still to have the welds tidying up then painted

[big mick 1981]

Finally got that big hole filled ................. On the bike of course lol

[big mick 1981]

Not a lot of progress with there being a slight cash flow issue just now .......... ****** Xmas lol








Yeah I know the colour is a bit bold but going to get some vinyl to break It up a bit





Also started swapping out bulbs for LEDs , what a difference they make