Fix of Front Brake

The front brake was full of "Slime" and it totally didn't work. After the engine running, I couldn't be patient to ride it soon. I tried to push out the slime but it was very hard to clean up them because the slime was getting hard in the brake system. I finally pushed out the slime, I installed new repair set of master cylinder and new seal for the piston of brake caliper. The front brake was fixed. Furthermore, I installed a dual disk kit from US (below picture). It is modified left hand caliper to fit the right side so the pipe work of brake was getting strange.

I thought it can't pass the car inspection with this brake pipe settings and the brake lever was getting too soft because the master cylinder was for single disk set up. Finally, I gave up the dual disk set up (after I took the license plate, I could get genuine right side caliper and it could have a dual disk set up).

Correction of "Leaned" Rear Wheel

I felt uneasy with the leaned rear wheel. This may not be a special symptoms because I've seen a H2 with leaned rear wheel in a motorcycle magazine.

The swinging arm is made by iron, so I believe if I apply a force on it, it will be back to the original shape. (please note this is truly dangerous correction method. Do it with your own risk!)

First, I removed the right hand rear shock. Apply a car jack (strange shaped jack for German car) between the suspension pivots of the frame and the swinging arm. Turn the handle slowly to open the car jack. I felt scared for creak sound but I opened the car jack slowly. As I thought, the rear wheel was getting straight. I thought "Hey, I've got it! It getting straight" but when I remove the car jack, it was returned to the previous position. It was returned like spring so I should open the car jack more. I tried again. I did the same treatment again but this time I opened the car more so that the rear wheel is leaned to the opposite side beyond the straight position. It was horrible experience because I wonder if the swinging arm was broken (I had a lot of cold sweat!). When I removed the car jack, the rear wheel is returned to the straight position. The photos below show the "before" and "after" photo.

Clean Up of Exhaust Pipes

The engine was fired up, so I tried to clean up the exhaust system (should I do it first?). Remove the silencers from the exhaust manifold and when I hold it upside down.... a lot of rust and carbon was come out from it (I should take the photos!). I cleaned up the manifolds and the inlet side of silencers with screw driver. I couldn't remove the baffles because they are stuck by rust so I did nothing for them. The exhaust gas was come out from the silencers so far and I think it will loose someday with the vibration during running. The outside chrome plating was cleaned with a steel wool soap pad. They have some small dents but I don't care about it!

Later, when I removed the baffle tubes, there are a lot of black tar inside of the silencers. I removed it with long screw driver, little by little.

Clean Up of Air Cleaner

The next is air cleaner. When I removed the cover of the air filter, there is a form filter that looks intact (when I fired up the engine, I didn't check it). I thought "Oh, it is looks clean" and I touched the filter..... the form filter was getting powder when I touched it. "OOPS!" I removed the cleaner unit soon. When I did the job, I didn't have the service manual so I didn't know that I should remove the side panel stay when I remove the cleaner unit from the frame. It was very troublesome job like puzzle. I thought "KAWASAKI's engineer is stupid" but real "stupid" was myself. The form of the air cleaner looks clean but all of them was getting a powder soon (again, I should take the photo!). When I come to think of it, if the powder was sucked into the fired up engine, the results was getting miserable. I thought deeply that before fire up the engine, I should check all of the things.

Needless to say, the air filter is not available from KAWASAKI, so I made it by myself with a plane form filter. I made a circle with a rectangular sponge form with epoxy adhesive. It was nicely fitted.

This isn't the end of the story, is it?

Okay, I'll go back to the home!