Author Topic: The Mosquito! (Kawasaki KZ250) (Read 47345 times)

Scott S · « **Reply #75 on:** April 01, 2011, 04:55:34 PM »

So we made some plates out of MUCH thicker metal and welded them on.

Scott S · « **Reply #76 on:** April 01, 2011, 04:56:51 PM »

Using this method, we were able to use the mounting plates that came with the rear sets.

Scott S · « **Reply #77 on:** April 03, 2011, 04:54:02 PM »

Restored my handle bar controls this weekend.

Scott S · « **Reply #78 on:** April 09, 2011, 01:03:37 PM »

Got the tabs for the side covers welded to the frame.

And some side covers fabbed up.

Scott S · « **Reply #79 on:** April 09, 2011, 01:04:48 PM »

Looks like we might have to massage the rear edge of the covers just a bit, but they look pretty cool, huh?

seanbarney41 · « **Reply #80 on:** April 09, 2011, 11:12:52 PM »

bead rollin' is a nice touch...!

Scott S · « **Reply #81 on:** April 15, 2011, 04:23:52 PM »

Big update this time. Well, it seems big. We've done a lot of work, but the pictures don't show all the effort we've put into it lately. Trust me....Dad and I have spent HOURS in the garage on this thing lately.
We learned how to shorten cables, fabricate rear-set linkages, etc., etc.

We reunited the engine with the frame, to start....

Scott S · « **Reply #82 on:** April 15, 2011, 04:27:01 PM »

For the brake linkage, we cut the stock pedal...

And welded a tab onto it so we could use the stock brake rod and brake light switch...

Hooked up the linkage and it works GREAT! Very firm and positive feel without have to move the pedal through a wide arc.

Scott S · « **Reply #83 on:** April 15, 2011, 04:32:08 PM »

For the shifter, we cut the stock shifter...

Mocked it up with some stiff aluminum wire...

And bent a stiff rod and threaded both ends to fit the joints we had. It also works great. I can easily get all the gears, even without a clutch cable hooked up or the engine running.

Scott S · « **Reply #84 on:** April 15, 2011, 04:33:17 PM »

We cut up the stock muffler hanger to make a center stand stop. This will be bolted to the left rear set bracket.

Scott S · « **Reply #85 on:** April 15, 2011, 04:36:54 PM »

We also went to the local bike shop, who graciously let us wander around in the back room, and we found a front brake cable that was the perfect length.
We had to cut and shorten the throttle cable, though. The clutch cable is getting shortened in the next day or two.
Installed the chain and carb, too.

hoodellyhoo · « **Reply #86 on:** April 16, 2011, 07:54:57 AM »

Wow that looks great! Glad to hear you're getting proper length cables. I hate it when guys "cafe" their bike (read: inastalled clubmans/clip-ons) and keep the stock length cables hanging out all over the place.

Scott S · « **Reply #87 on:** April 19, 2011, 05:20:12 AM »

Got 98% of the wiring done. The rest will be figured out once I have a battery in the bike and can test a few things.
I mounted the fuse box on the inner fender, under the seat. I had a spare fuse box from a junk wiring harness, so we gutted it and mounted it to use as storage for spare fuses and maybe even registration/insurance cards.

Scott S · « **Reply #88 on:** April 19, 2011, 05:23:02 AM »

I bought some "idiot lights" for the neutral and high beam indicators. Using the rubber grommets for the stock handlebar risers....

....we installed them in the triple tree, along with the mini-gauges. Pretty clean look, huh? I'm thinking the ignition switch will go in the center at the front of the triple tree. Still have to work that out.

Scott S · « **Reply #89 on:** April 19, 2011, 05:24:55 AM »

The tank, while mounted firmly, still had a little side-to-side wobble. I wasn't happy with that, so Dad came up with this solution. This makes the tank much more secure and still gives just a little.

Scott S · « **Reply #90 on:** May 02, 2011, 01:19:39 PM »

We needed a dash to mount the key, so we cut up some scrap metal, bent it to shape and sprayed it with wrinkle paint.
We used some existing threaded holes on the triple tree to mount it.

Scott S · « **Reply #91 on:** May 02, 2011, 01:21:18 PM »

...And...bodywork has begun. I'm going to paint this one myself. I've had some pretty decent results using spray bombs and Maxx2K 2-part clear coat in a can.

Scott S · « **Reply #92 on:** May 08, 2011, 03:49:14 PM »

Finished the bodywork and painted the tank and seat. This is a spry-bomb job, done with Dupli-Color and SprayMax 2K clear coat.

Scott S · « **Reply #93 on:** May 08, 2011, 03:50:42 PM »

For the exhaust, we used the stock head pipe and this stinger...from a VW Beetle! We cut of the three bolt flange and made a hanger bracket.

Scott S · « **Reply #94 on:** May 08, 2011, 03:52:03 PM »

Then had our local muffler shop weld up some pipe. For a baffle, he cut a piece out of the innards of a Corvette side pipe! Fit's perfect.

Scott S · « **Reply #95 on:** May 08, 2011, 03:53:22 PM »

Painted it with 2000 degree exhaust paint and installed it tonight.

CBJoe · « **Reply #96 on:** May 10, 2011, 04:12:16 AM »

Bike looks freaking amazing.... very interesting how you changed the frame profile from the lower slung seating to where it's at currently.

Scott S · « **Reply #97 on:** May 12, 2011, 04:45:31 AM »

Rigged up a fan and a gas can and got her running. We won't be sure until we can ride it a bit, but it may need re-jetting. It's close....real close, especially for a carb that wasn't originally FOR this bike.

Scott S · « **Reply #98 on:** May 12, 2011, 04:49:16 AM »

And here's a sneak preview....
I ran out of daylight for better pics. It's about 98% done here. Still need to lube the chain, tune it just a tad, and I have some killer badges being made for the tank.
Oh, and I have a leaking petcock. I hate petcocks. I'm batting a thousand when it comes to petcock trouble. EVERY single bike I've ever built has had petcock issues.

seanbarney41 · « **Reply #99 on:** May 12, 2011, 01:37:42 PM »

Looks great...a ton of fun in a three hundred lb package!

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Author Topic: The Mosquito! (Kawasaki KZ250) (Read 47345 times)