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 Can a KE100 go cafe? Let's see ...

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Posts : 40
Join date : 2011-04-13
Location : Warsash, Hampshire

PostSubject: Can a KE100 go cafe? Let's see ...   Mon Apr 18, 2011 7:21 am

Well, having missed my old bike for a couple of month I came across this little beastie at a suitable project price. The actual condition isn't bad, chrome in the wheels is very good and the rest of the bike is in good shape for its age. The guy I bought it off had put new tyres and fork seals on it but was selling due to too many other projects. The bike has been off the road for the last 6 years so will need a test but shouldn't be too big a problem. 
When I went to see it he said that it was smoking a lot ( even for a 2 stroke ) and that a few other bits including the kill switch needed fixing. So anyway, a deal was struck and I brought it home.

There was a little bit of surface rust on the frame so I stripped the bike down, sanded the rust back, applied a bit of kurust and then a lick of smoothrite. Job Done! looks much better now. Also partly stripped the engine as the air box needed a coat of paint and found there was no gasket on the carb cover.



Gave everything a good clean up and has now been put back together again at the same time I also removed all the stickers and repainted the exhaust shield black. She fired up first kick and the smoke cloud issue has pretty much gone Very Happy. When she was apart I also cleaned up all the electrical connections and hey presto a working kill switch. 
Tried some plastic polish on the body work but I think its a little beyond saving so have been looking around am thinking of getting the side panel and rear guard wrapped in a gloss black vinyl. I also need to strip, repair and repaint the tank as its managed to get a little dent at some point which has cracked the paint. Im hoping I will be able to find a can of the kawasaki green paint and do all this myself to keep costs down a little.
Also treated the old girl to some colour coded brush guards and a pad for the handlebar Very Happy

Just need to do a few more checks and then I will put her in for her test.
The bike went through its test today and has been taxed so she is all road legal again. Had more fun on it that i thought on the ride home  Its quite nippy for a little 100cc buzz box
Have now decided to keep this and have a 'play' with the style of it in a similar vein to the old shadow. With that in mind I have ordered a set of clip ons, rear cafe racer style seat unit and will be starting the transformation as soon as they arrive. Will get some pics up when the process begins 
well new bits turned up...


so started to strip it down for a first mock up


and then added the parts. Need to make a front screen and something to hold the clocks. Not sure about the bars but have my eyes on a different style that may work better. Also need to trim the rear of the seat to follow the lines of the bike better


Got the bike more stripped down now and got the seat unit sitting properly. Just need to get a couple of bars welded across the frame to bolt it to.

Then stripped her fully so i can take it to the jet wash to clean it down. Will need to decide if i should get it sand blasted and sprayed or just give the paint a touch up.

Also won some new bars on eBay which should fit the look better. Need to make something to fill the gap between the seat and tank then i can start on the engine.
Well had a bit of a result and found a local chap who could blast and prime my frame, swing arm and tank for £40! needless to say it went off to him and came back this afternoon. Well happy with the results and if the weather holds out i will try and get the frame painted tomorrow in the metal flake red.


Also got the rear lights fitted, exhaust tidied up with a bit of wrap and the front forks rebuilt with new seals.



Ordered a set of small bar end mirrors and a smaller number plate to fit on the back of the seat unit. Busy weekend so far!!!
well managed to get the frame & swing arm painted yesterday. Its a deep red with metal flake in it but its pretty difficult to get a decent photo of! Also got the seat unit in primer ready for the satin black top coat for that and the tank. Also picked up a fairing for it which i think will fit in quite well with the style im going for once its painted to match.

Got the first couple of coats of paint on the tank and seat last night. Front fairing should be turning up today so i can get that primed and painted soon too. Starting to get there which is good as i only have 2 months till TT!

Thought i would have a quick mock up last night as the fairing arrived. Obviously it needs prepping and painting to match the seat and i need to fabricate some lower support brackets but im fairly happy. Will be making it sit about an inch or so higher then it is the the picture and adjust the dealight to suit.


Need to get the wheel centers painted this weekend, sort the wiring harness and tidy up the rear suspension. Also going to be ordering a side number oval panel which will be hand painted with a silver and black chequered background and a red 5 ;-)
Its starting to get there now at least
 Well got a bit more done today. To be honest im starting to think it looks more Mad Max than cafe racer but im guessing thats down to the motorcross base bike. Still liking it though. Have about an hour or so's work left to do once the last bits turn up but she is getting there.







Few more pics. Sorting out the wiring and still waiting for a few bits to turn up but its getting there...


Well i got the wiring all finished today, got the chain back on and basically im just waiting on the side plate and its finished. The foam for the seat turned up but i cant get a nice end to the cuts at the moment so need to figure that out. As the weather was so nice i figured i would wheel it outside for a few pics! still cant decide if i prefer it with or without the fairing though.




This is where i am currently at, im leaning more towards the non fairing look at the minute which is a pain considering that was probably the most expensive part! lol. Would need to change the clocks then though. 
There are a lot more pictures if your really bored and want to waste some time Smile
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