JDM (Japanese Domestic Market) Kettle Restoration

[oldjapanesebikes]

[RING_DING]

Two of the four fork pinch bolts have "S" heads and two have flat heads and are chrome plated. Just wanted to make 100% sure, but I assume the chrome head bolts would be the ones for the lower tree, being more exposed to view?

[RING_DING]

I haven't posted any update in a while, but the reassembly continues. The motor is back in the frame. I decided that "if it ain't broke don't fix it" so I didn't do anything to the motor apart from a thorough cleaning on the outside. I know, I know....those crank seals are eventually going to go, but I was reluctant to start tearing into the motor when I knew I'd be facing huge expense getting crank & seals redone, not to mention whatever else I might find in there. The motor was running very well prior to the resto so I'll just keep running it until the time comes for a motor teardown. It's easy enough to get that motor out.

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I recovered the seat with a new cover from Pit Replicas. These covers have been reviewed on the Forum before, and this is the second one I have done. I think they look really good compared to some of the other replacement seat covers out there. I was able to reuse the wires and the clips from the old seat cover, and I have to say that the overall fit & finish looks pretty good.

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On to the front end.....the original fork legs are badly pitted with rust:

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Thanks to Forum Member 2StrokeTony for coming to the rescue! He happened to have a set of M model forks that he was looking to move so I got those from him. The stanchions are in great shape. The fork lowers on the JDM bike were in reasonably good shape and there is a Japanese language sticker on the RH lower. With a bit of a polish, new fork seals and the stanchions from Tony, they are now ready for mounting.

[oldjapanesebikes]

Nicely done !

[RING_DING]

You may recall how the headlight looked when I first got the bike:

Headlight Bracket.jpg

Note the special bracket that holds the headlight alignment. This was unique for the Japanese Market. Even though the headlight shells had the exact same part number, the JDM shell has a bolt hole and a dimple for the attachment of the bracket:

Headlight Bucket 2.jpg

I have a spare non-JDM headlight bucket in good condition but I would have had to modify it to attach the alignment bracket. In the interests of authenticity, I decided to get the original headlight bucket rechromed. Here it is in place after rechroming:

Headlight reassembly.JPG

[oldjapanesebikes]

Looking good Roy !

[RING_DING]

More progress since last post......
I rigged up the instruments temporarily (before I send them off for Allan to work his magic on them) to make sure I connected all the right wires. Everything electrical worked! For those curious, that is a 1975 MG Midget in the back...my other winter project.

Electrical Test 12-13-2012.jpg

Motor with carbs mounted. Once I have the rad and pipes back on I'll do a test start before I put the airbox & oil pump covers back on:

Motor taking shape 12-13-2012.jpg

View from the back. Tank is out getting re-painted to the original color (Olive Green). Won't be long now!

View from rear 12-13-2012.jpg

[pearljam724]

Looking good, Roy. I may be facing the dilemma of removing my motor on my own and I think I may copy your technique. Did you put it back in, the same way you took it out? How did you come across the JDM? Luck or did you know what you were looking at before you bought it?

[RING_DING]

Yes it went back in the same way, very easy. Just got to make sure the dolly doesn't run away from you when you tip it over vertical again
I only discovered it was a JDM after I got it. I found Ian Sandy's Field Guide after a Google search and contacted him directly via email. It was after Ian had spotted a few unique features in the pics that it was positively identified as a JDM model (it is a B-4, equivalent to the M in the rest of the world).
Check out this thread for more info and pics of how she looked when I got her:
viewtopic.php?f=20&t=4679" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;

Side story: my wife was horrified when she arrived home and saw this standing in the driveway. I had just sold a 2003 Aprilia Caponord to make room for a project bike. She found it difficult to understand why I would sell a perfectly good bike and then buy this "piece of junk" (I paraphrased her exact words)

[ConnerVT]

Well, your diamond did have a few rough edges when it first arrived.

My wife also questioned my sanity when my T500 showed up. Probably even more so, once I had it all apart, with pieces scattered throughout the garage, basement, and shed.

My son (14) was the first to notice the change that was taking place, amazed as how 'shiny' I was making the 40 year old chrome parts. My wife finally came around, after seeing how much joy I had as the parts finally started being reassembled, and the grin on my face each time I come back from a ride.

[RING_DING]

Borrowed the tank off the Red M and took her out for a shakedown ride. Some small adjustments required to brakes but running well.

12-28-2012 Shakedown ride.jpg

Got the tank back from the painters. The color match to the original is amazingly close:

12-28-2012 Tank 1.jpg

12-28-2012 Tank 2.jpg

[oldjapanesebikes]

Sure looks the business Roy !

[RING_DING]

Thanks Ian! Got the tank and side covers on this morning. Just waiting on some new tank badges. The side cover badges are the originals and they are not in bad shape. Took here out on a 40 mile ride this afternoon. Stopped at our local "ethanol-free" gas station for a fill-up. Everything seems to be running well. Face a bit sore from grinning ear to ear. Here's a couple more pics taken today after the ride:

[RING_DING]

The credits:
Fork stanchions - 2StrokeTony
Radiator - Coyote
Front fender - Pearljam
Clocks - Suzmokeyallan (in advance!)
Genealogy - Oldjapanesebikes
Everything else - thanks to all you Forum Members - I could not have done this without you

Happy New Year everyone!

[two-stroke-brit]

roy whats the story on the scratch in the nice gray tank.?
lovely build by the way
cheers mark