JDM (Japanese Domestic Market) Kettle Restoration

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I decided to start a new thread to record the restoration progress. Many of you will recall how this story started:
viewtopic.php?f=20&t=4679" onclick="window.open(this.href);return false;
I got this bike somewhat cleaned up and running, and took her out to Deals Gap in May of this year. She really performed well so after a lot of back & forth, I decided I would embark on a full restoration. I've done some mild customizing on my other Kettle (the Red "M") so I have some half decent stock parts to fit to this JDM bike. As it turns out, this JDM B-4 model is exactly the same as the 1975 "M" with the exception of some JDM-specific parts so I have a model bike to compare to!

Here she is down to the frame & motor. I followed Ian's method to remove the frame from the motor by flipping it over onto it's side. As I was standing in my garage looking for some means of blocking the engine when I laid it over, our Christmas Tree holder caught my eye. The opening measured slightly larger than the stator cover so I thought I'd give it a try. Well it was a huge success! With the frame sitting on a mover's dolly, I flipped it over onto the tree stand. Lo & behold, the motor fit perfectly and it made a secure & stable platform as you can see from the pics.

A visit to the local powdercoating shop is next.

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Out with the kerosene to get the oil & grease off before handing this lot over to the powdercoaters. My wife was amazed at my cleaning skills which had been carefully hidden all these years

[oldjapanesebikes]

My wife was amazed at my cleaning skills which had been carefully hidden all these years

Ouch - you realise of course that you are now doomed eh ?

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I found this relay attached to the frame top tube right behind the coils. I don't have one on my red M bike, so I think this is the relay for the JDM-unique speed warning light on the dash.

[Suzsmokeyallan]

I often wondered what went onto that little flat bracket, most of the times the harness sits right on it for support.
It think it might be a buzzer as most of the relays you can open, this one has a poured cover on the end to possibly stop people from tampering with it. Whats printed on the end cap of the little can.

[oldjapanesebikes]

It isn't a buzzer Allan - its the relay (part number 34990-31011) to operate the 80kph warning lamp used on JDM models. I posted the full Japanese model parts manual (well - up to 1975 at least) at this link - look under 'Meters B3+':

http://www.oldjapanesebikes.com/mraxl_G ... index.html" onclick="window.open(this.href);return false;

And also at this link:

http://www.oldjapanesebikes.com/fieldgu ... html#Japan" onclick="window.open(this.href);return false;

Quite rare outside of Japan Roy - don't lose it ! I have a wiring diagram I can send you for it - the colour codes are in Japanese, but you can trace the wires and figure it out if you are interested.

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Allan, here's a couple more pics of the relay. There are no markings or numbering of any kind that I can see on the back or around the circumference.

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Here's a standard headlight bucket alongside the JDM version. The part numbers are the same, but I've highlighted the fixing points for the special bracket.

[Suzsmokeyallan]

Thanks for posting those photos up Roy, I'm surprised there are no markings on it as normally they have some info printed on the base as they do on the flasher relays.

You mentioned the headlamp bracket and notice the left head lamp ears lip has a cut away part on the lower section for the adjuster bracket to clear it.
For some reason a few of the non JDM models left ear brackets did not have this cut away and some did. It seems strange they would make two styles of left ear but they did.

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SWMBO was out of town when I got the frame and other black bits back from the powdercoaters. This is the closest I'll ever get to having a bike in the house!

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Thought I'd try a sample area for some case polishing last night. Some 800 grade wet & dry in soapy water, followed by Blue Magic and the shine is starting to return.

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I managed to remove this decal intact from the frame before it went off for powdercoating. Any suggestions for what type of adhesive I should use to stick it back on? The decal is very thin and curls easily. Looks to be some kind of foil-backed material.

[Suzsmokeyallan]

The thin double sided adhesive tape that resembles scotch tape will work for that decal Roy. Its available at most places such as Wally World, Office Depot etc.

[oldjapanesebikes]

+1 to Allan's comment - I suspect you've already scanned it just in case you want to make another one ?

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I'm learning some Japanese with this project....I need to look up "Luburication"