Kawasaki ER-5 Cafe Racer

[Exuptoy]

Got half hour earlier and tried the Ali Express front guard which was too big for anything bigger than a 125 really as the mounts were too narrow for the 110 front tyre and the curved section was a little too small. I decided to drill out the spot welds, fitted my recently acquired CB900F fork brace and wedged it up inside. Doesn’t look too bad I think.

Also got my bar end mirror with flashers. They have yellow winkers and a white running light. Nice enough for less than £20 ($24)

 

[Exuptoy]

Cut my tank mount off and lowered it a little to close the gap between the tank and upper frame tube and I reckon it looks better.
Cut my subframe brace and inserted it with the aid of a 2lb hammer, cut a piece of 8mm thick plate to use as a rearset mount and tacked in place, got my new welding torch so started to run a nicer weld on the right hand suspension support tube then ran out of gas!!!
The pics below are how it currently sits until I get some gas.

 

[Exuptoy]

Got my M8 10mm high tensile shouldered bolts arrived to fit the caliper so that’s one job complete.

Also got my rear wheel. Love the look but may be too big. Can always re-rim it with a 4.25x17?
What you guys think?

 

[Jimbonaut]

I like it. Looks...boisterous

 

[Exuptoy]

I need an 18inch front to match the Z650 rear with a single front disc. Anyone have an idea of a suitable rim?
Z400, Z305???? The 650 front is 19!

 

[Exuptoy]

Haha, Boisterous...I l that!

I think that’s it’s new name!

 

[Exuptoy]

 

[Maritime]

Right wheel on front and it will look great

 

[Exuptoy]

I won a KZ305 front 18” wheel this evening for £70 inc the tyre. Hopefully it’ll work out ok.

 

[teazer]

I know it's still on a lift, but have you measured swingarm droop and steering head angle by any chance and will the chain line clear the frame as well as the swingarm? The reason I ask is that it looks a few degrees steeper than I'd expect, but that may just be an optical illusion

 

[Exuptoy]

I purposely left the LH suspension unit attached until the RH was complete to ensure I’d not altered the rake and trail. The only thing that has changed is the length between the swingarm pivot and shock mount, the angle of the shock was adjusted to be more vertical to maintain the spring rate after taking into account the longer shocks. Also the shocks are from 2017 Triumph Street Twin which actually weighs more than the ER5 so I’m not too worried.

 

[Exuptoy]

KZ305 front wheel fitted, tyre is cracked so I’m gonna try and upsize it a little to get some proportion to the rear tyre. Looking at the wheel size at 1.6x18 and 2.15x18 I’d say a 90/90 and 130/80 are about right. I’d like to push the front to 100/90 but think it’ll be too big. RH wheel spacer is gonna need light machining to get the wheel central but I’ll have to turn up some kind of boss to accept the ER5 disc. At least I’ll have modern brakes on the front.

 

[Exuptoy]

I recently purchased an old Atlas lathe so I can make my own spacers and the like, and after getting a ratty z650 rear which the spokes were rusted, I decided instead of using the wheel that I’d use the wider rim on the front.

with that in mind I hacked out the rusted spokes, mounted thehub in the lathe and machined and trued all edges and skimmed the drum back round.

I also stripped the paint from the rim and dropped it into my local chroming place to strip the chrome and nickel do I could get it powder coated.

Once I get the rim back from powder I’ll strip the front down and fingers crossed I can re-use the spokes and mount the wider rim.

 

[Exuptoy]

Got my new lathe bench built and painted, and mounted the lathe, so today I made a few spacers to mount the wheel central. Just the rear left now.

 

[Exuptoy]

Got my rim back from powdercoat.

 

[Exuptoy]

Tonight’s work was to line up the wheel which was made easier with a piece of string and my eye! Following this I used my chain monkey laser to check the chain run, you can see the laser dot on the front sprocket.
Next up was a captive spacer which I turned up on my little Atlas lathe. One more left to do.

 

[teazer]

getting there. one step at a time. I have lathe envy now.

 

[pidjones]

Lathes, even my little 7x10 Harbor Freight, can be so useful in bike work.

 

[Maritime]

I think a lathe should be added to my shop soon

 

[Exuptoy]

getting there. one step at a time. I have lathe envy now.

I’ve been fortunate to find work during this pandemic which is limiting my usual garage time but a little bit of work every few days should keep pushing this forward.
The cost of the lathe wasn’t too bad at £300 but I’ve spent the same again building the stand and on repair parts to get it up to scratch like taking out the backlash in the travel etc and on tooling but it’s there now and is more than useable. It’s actually 80 years old!! I love it!

Lathes, even my little 7x10 Harbor Freight, can be so useful in bike work.

I think a lathe should be added to my shop soon

Once you own one you’ll wonder how you managed without one? Plus putting a machined edge on a bar or spacer just isn’t the same on a grinder.