Topic: Kawasaki Ninja 600 starter clutch repair, motor and body work done

[MoMo]

Thinking of buying a pair of Ninja 600s, one needs starter clutch and the other has bent forks.  Owner wants 600$.  It seems as though the motor needs to be split for starter clutch repair, anyone know for sure or if there is a way to access through the bottom?  Thanks in advance..Larry

[Retro Rocket]

http://www.zxforums.com/forums/mechanical-technical/46933-zx600-seeking-starter-clutch-installation-advice.html

Does that help..?

[MoMo]

thanks RR, looks possible from viewing that thread...Seems like it could be a good deal if that is possible...Larry

[Killer Canary]

It's a good deal even if it isn't possible.

[MoMo]

It's a good deal even if it isn't possible.

Yeah, might take awhile but I should be able to get both bikes streetable without an exorbitant amount of money...thanks for the feedback...Larry

[Killer Canary]

If it's a 600E I have the Clymer for it.

[MoMo]

If it's a 600E I have the Clymer for it.

Not all that well versed on Kawi models, one is a black 89 and the other a  white 93.  If I get a chance I'll try to put up a couple photos-right now both are buried in the back of one of my storage sheds...Larry

[Killer Canary]

A D and an E.
The manual covers both.
If you want me to look anything up, let me know.
They're generally well engineered machinery; stayed in production til the 2000s.

[MoMo]

A D and an E.
The manual covers both.
If you want me to look anything up, let me know.
They're generally well engineered machinery; stayed in production til the 2000s.

Thanks, the sale is still up to the owner ...I did some work on a Ninja 250, which was a nice little bike. May buy an older 750 turbo.  Never owned a Kawi...Larry

[Killer Canary]

Kawi didn't produce anything in the early 80s to be ashamed of. I have an '85 GPz900 and it flies.

[MoMo]

Kawi didn't produce anything in the early 80s to be ashamed of. I have an '85 GPz900 and it flies.

I even liked the Eliminator model, can't remember if it was a 900, 1000 or 1100 but it was a long, lean, mean looking machine

[Killer Canary]

The first bike that I ever bought from salvage and restored was a '93 ZX600. I spent weeks repairing and painting. Prism pearl white and Kawi green. I rode it all of that summer. Then in late August I sold it to a guy who missed the very first curve on his way home and folded it in half.
I had my money, but it hurt to see such a worthy machine in so horrible of a state.

[754]

Do you know a guy in the salvage biz in Sask, first name Graham...
 He used to have a yard here in town..

[MoMo]

Well it is possible to repair the starter clutch without pulling the motor   I buttoned up the oil pan, clutch cover and left side cover then took the bike for a short spin. thanks again to Retro Rocket for finding the thread, it was instrumental in giving me direction to pull of the repair. 


Still need to repair all the cracked plastics but this should make for a fun bike.  I also sold the other 600 Ninja today so I'm left with two Kawasaki's-my new to me Concours and a 600 Ninja.

[MoMo]

Oh yeah, found this pinched wire during the repair process.  Believe it is a wire from alternator, after making a repair to the wire I checked charging and found it to be minimal- a shade of 13.5v ...Larry

[MoMo]

I paid 600 for both.  Twisted front end on the 89 was a bent steering stem.  $25 off ebay with free shipping and the bike was good to go.  I did some other work(mostly moved good parts from the 91 to the 89 and bought a new rear tire and replaced front brake pads then Sold it for 1500


Parts to repair the 91 were less than $100, also bought a pair of tires, battery, clutch cable, clutch lever and it should be good to go mechanically.  Fellow forum member is going to plastic weld the numerous cracks in fairing, side covers, rear cowl.  I've been searching ebay for non-broken plastics.  Tough to find....Larry

[MoMo]

Well, it took a looooong time to finish the body work but the Ninja is finally done(at some point I will repaint the tail piece). I bought two Ninjas for $600, one with a bad starter clutch and the other had a bent front end.  I bought a steering stem to fix the bent bike, replaced tires, brakes, chain, tune up, oil and filter and sold it for 1600 to a friend(book value was closer to 2500 for a 1989 Ninja 600.

I repaired the starter clutch without taking the motor apart, bought a NOS left front fairing for $100, repaired some cracks in right front fairing, replaced tires, brakes, etc.  blah, blah, blah but was unable to locate a rear piece that had all mounts intact.  Finally found one on eBay for the great price of $31 with free shipping.  However, the paint is a tad different.

All those bungee cords are all that holds up the rear tail piece

IMG_0431 by Lawrence Moulder, on Flickr

IMG_0433 by Lawrence Moulder, on Flickr
IMG_0438 by Lawrence Moulder, on Flickr


Here is the new tail piece


IMG_0455 by Lawrence Moulder, on Flickr


I may paint the side but this is staying


IMG_0457 by Lawrence Moulder, on Flickr