Saturday March 22nd 2025

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Saturday March 22nd 2025


Kawasaki KZ550 (ish)


Graham and Andy J worked on the bike’s front brake to try and bleed the air out of it and get it working.  Nothing they could do could get rid of the air in the fluid, where was it coming from?  No matter how much fluid was drawn through the pipe/caliper it contained a steady stream of bubbles.  In the end there was nothing for it but to disassemble the master cylinder and take a look. It was whilst checking it out that Andy J noticed that the piston in the master cylinder appeared to be too small in diameter to fit the cylinder and a new cylinder would have to be ordered to get the brake working.


Braking News - No front brake for the time being.



Kawasaki Z250 Scorpion.


Keiran worked to make a plate in order to attach the original tail piece to the bike. He checked the bike out looking for the final bits and pieces to do to complete the bike. These included to make sure the front brake light switch could be made to work; checking where the wiring for the read light switch could be found. (It was hanging around with nothing to do at the rear end of the frame’s top tube. The bike would also need a pair of indicators to fit at the front end, along with a new rear brake light switch and a pilot light bulb holder to fit the pilot light into the headlight. Keiran left the session with the intention of identifying a source for these final few parts. The new fuel tap still needed to be fitted to the tank. If there was one the vacuum connection for the original vacuum tap would need to be located and blanked off. Other conundrums that Keiran had turned his thought to were a) How to encourage the neutral light to come on and b) How to replace the missing light switch that should be fitted in the right hand handlebar switch assembly but was noticeably absent. Would it be possible to fabricate some from a piece of steel strip or would be economically viable to replace the switch assembly?

It looked as though the Z250 had taken a backward step - but investigation was needed to get it completed.




Is this the final 'To Do List for the Z250?

Suzuki Bandit 1200


We had hoped that the carburetor repair would have turned up in time for this workshop session but they were still a couple of days away.  However Steve was able to clean up the top of the crankcases, the alternator was even removed to clean up under it and to polish up the bare metal of the alternator.  Steve then applied a couple of paint areas of the cylinder barrels and the top of the crank case where the original paint had begun to come off, freshening up the engine. Steve also spent some time encouraging the new carb to air filter housing rubbers to fit into the air filter housing. So it would have to wait until we could get the inlet manifold rubbers refitted, the carburetor repair kits fitted and the engine running once more.

Small steps for the Bandit at this workshop session but every little counts.


Jialing 125 trails bike project.  


In the blink of an eye Keiran had turned the uncomfortable seat base into something with a modicum of comfort by adding foam and a vinyl to cover it and very professional it looked to.

The former trail bike was now ready to go trialing.


Honda Vigor.


Mal did more work to improve the looks of the bike. Having previously done a great deal of on the front end and finished the engine Mal stripped and began to clean the rear end of the bike.

Work slowly progresses rearwards to refurbish the Honda Vigor.