Teardown: frame nearly finished and ignition issue

By | 1st June 2013

The frame is nearly ready to be stripped and coated. Just need to get the races out of the headstock and do some preliminary chemical stripping and rust removal/treating. Getting the races out could be a job. There’s a special tool from Kawasaki for doing it, but it’s silly money and in theory some kind of drift should do it, I hope.

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Frame nearly ready for stripping and painting

Manky, rusty front mudguard

Manky, rusty front mudguard

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While tidying up, I had a look at the ignition switch (faulty) and thought I could see some fraying wire. A new one is hard to come by (used, actually) and I’ve looked at the possibility of re-wiring with a new, aftermarket switch. Figuring I had little to lose, I had a go at getting the switch apart. A bit of grinding to remove a stripped screw got the the mechanical, key switch away from the electrical switch assembly and I then managed to get that open to find an obviously frayed connection. Typically, I then took it a step too far and the various mechanical bits underneath went “ping” and I didn’t know how it went back together.

This looks rather iffy, if difficult to see

This looks rather iffy, if difficult to see

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Managed to get the ignition assembly apart without breaking much.

Managed to get the ignition assembly apart without breaking much.

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This all went "ping" and I'm not sure how they go back together.

This all went “ping” and I’m not sure how they go back together.

Dirty contacts

Dirty contacts

I think I may have re-assembled the bits right, but not sure. I intend to give it all a good clean, re-solder the bad wire and hope that it works!

Re-assembled switch-gear. Not sure it's gone back together right.

Re-assembled switch-gear. Not sure it’s gone back together right.

 

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Connection nearly broken

Connection nearly broken

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