Installed magneto and flywheel

After re-installing the magneto and flywheel, I cleaned up the connections and reconnected the wires.  I decided to leave the ignition coil for now, even though I already purchased a new one.

I will clean the case when I install a new chain.

Fear the key!

New points and condenser

Tonight at work (in between calls) I rebuilt the magneto/points plate.

(before)

Points removed

Cleaned up and tested; I priced replacement felt pads and ended-up reinstalling the original after snapping this.

I hope it works as good as it looks here.

Pulled flywheel

Today I pulled the flywheel in order to replace the points and condenser.  I was happy to find out that one of the flywheel pullers that I already owned was the correct one.

The right tool always helps.

puller tool information

Loaded the bike into my truck

I had originally planned to tie the bike down, next to my KLR650 in the bed of my Chevy Colorado.  Since I purchased a second project bike and because I will be moving out of my storage unit a week prior to driving home, I decided to try and put the little D1 behind my seat.

Installed wheels

I ran out of time yesterday, so reinstalling the wheels with their new Shinko 244's had to wait until today.  The new rubber really seems to breath new life into this old once-forgotten machine!  I removed the front fender because the new tire was rubbing on it's side brackets; I'm thinking about mounting the fender, without its side brackets to the lower fork clamp to mimic the J1TRL.

It would have been nice to be able to change the chain and sprockets at the same time, but the sprockets were unavailable at the local Kawasaki dealers.

As a side note, I finally remembered to take a better look at the jug and was quite pleased to see the 99cc mark.  So, maybe it is a D1?

Now she rolls!

I can use the side stand now!  With flat tires, it didn't lean enough for my comfort.

Lets just call it 100.

New tires

Revzilla rocks!  I ordered these tires, tubes and tire irons on Monday afternoon and they came today.  This bike, I believe, had the original front tire and it was really dry-rotted.  Neither tires would hold air for even twenty minutes, so I chose to replace them even though the bike is not ready for them.  At lease it will be easier to roll it around while working on it.

Kinda cool how Kawasaki integrated the speedo gearbox with the front brake drum, but looks like a pain to install

Using my truck's jack to keep the bike upright

The old tires didn't fight too much

The bike will have to wait until tomorrow morning to get its wheels back

Cleaned and lubed throttle tube, cables

Although the throttle was functional, it felt pretty bad.  I disassembled it cleaned and greased the mechanism inside the bar and tube.  I had never encountered this type of throttle design before.  The grip tube has a corkscrew shaped ridge inside it, which meshes with the groove in the cable end-- changing a rotating motion to linear movement.  All metal parts, and the old grease had sand or some other gritty substance stuck in it.  After a good cleaning and a little grease, it moved much better.

I wanted to replace the switch pod mounting screws, and purchased some 5mm ones.  Either the thread pitch was wrong, or the screws are not metric so I had to install the originals with stripped JIS heads.

I guess the handlebars have to remain OEM

The cable sheath mounts in this anchor, which drops into a slotted part of the handlebars

The blue stuff is brake grease; its the only thing that I had with me

I noticed that the fender had been stamped 18-8 SS, nice!