[LenLanetti]

I have recently acquired a 1989 KE100...first bike I've riden in over 30 years....lots of fund and it is in very nice condition but needs some minor fixes...including replacement of the headlight sealed beam (US model). I bought a new 6V sealed beam and taken the old unit out of the headlight bucket. The old sealed beam is inside of two rings and looks to be held in with retaining clips. Is there a secret to taking the retain clips out? Or does the sealed beam come out some other way?

Thanks,
Len

 

[bweighmaster]

Maybe a parts breakdown would help . Partzilla.com has one ... Or try Manualslib.com ..for a PDF version of service manual ....And , Welcome to the forum ....

 

[WFO-KZ]

I got a chuckle out of what was probably a typo. You said your bike was "lots of fund". A perfect play on words.

No doubt it is a lot of fun but it may also take up some of your funds to fix it up and maintain it.

I am really stretching my memory here but I am pretty sure those clips just pop out. A good photo or two would help us figure it out.

 

[WFO-KZ]

I looked it up. Yes you just need to pop those clips. They might be rusted in though, so you might want to try some rust remover or penetrating oil on them first.

 

[bweighmaster]

Last one I had was in 1974 .... Many moons ago ....

 

[LenLanetti]

I got a chuckle out of what was probably a typo. You said your bike was "lots of fund". A perfect play on words.

Oh, that is a common typo for me...I work in financial services and spent about 40 years working with mutual funds...so my fingers just auto add the d at the end...so far not a lot of funds. Biggest issue right now is common metric fasteners...back in my motorhead days I had a large collection of odds and ends to go to...not so much anymore. :<)

 

[LenLanetti]

I looked it up. Yes you just need to pop those clips. They might be rusted in though, so you might want to try some rust remover or penetrating oil on them first.

I was thinking that's how they came out but they are jammed in there pretty tight and don't want to break anything while getting them out. Thanks. I'll squirt them down with something.

 

[WFO-KZ]

If I remember correctly, a good pair of needle nose pliers will remove the clips.

And yes, I can appreciate the "auto correct" of fingers that are use to typing the word funds. I have similar problems with other words.

 

[LenLanetti]

If I remember correctly, a good pair of needle nose pliers will remove the clips.

Here is the back of the headlight reassembled...still missing the adjusting screw, spring & nut (waiting on those parts). Flat head screwdriver to pry up on the center hump of the steel retaining springs (3 gold colored - 1 o'clock, 5 o'clock & 9 o'clock in the picture)) to take headlight out from the back. I did have to take out one of the screws, lock washer and nut that holds the inner ring to the outer ring (11 o'clock & 5 o'clock in the picture). Thankfully I did not have to take out both because one of them is not the correct part and jammed in there good. I propped the outer ring face down between two books flat on the table so the headlight could drop into the ring. One end of the spring clip can be pushed under the lip then used sturdy needle nose plyers to push the other end of the spring clip under the other retaining slot.

 

[WFO-KZ]

Great photo and good write-up. What's next on the list?

 

[LenLanetti]

What's next on the list?

Have to mount exterior headlight ring in the bucket. The ring is beat up a bit and non standard parts (sheet metal screws I think) were used to mount the ring to the bucket at some point in the bike's past. I will try to make that a little better but the screws that I took out might be what I end up using.

After that:
- Fuel lines are currently held on with zip ties (kind of neat but they are leaking) - fuel lines seem brittle. So, change fuel lines (use screw clamps) from petcock to fuel filter and fuel filter to carb & R&R fuel filter...changing fuel line to carb means taking the carb case cover off (rotary valve engine with carb intake at the bottom of the cylinder, right side). I will adjust air/fuel mixture...feels like it is running rich. I just received a set a engine bolts so will use some of them when fitting the case cover back.
- The horn was not held in place with any bolts, just dangling...luckily it looks like some of the case bolts will fit the threads for the fasteners for the horn so two of those case bolts will be repurposed as horn bolts.
- Replace current 14 inch shocks with 12.5 inch shocks (I need the seat to be a tad lower). Waiting on delivery of air adjustable, spring adjustable shocks now.
- Clean or R&R air filter, change oil, change spark plug (might move up one heat range), adjust chain, lubricate chain.
- Unfortunately, the headlight aim adjusting screw and nut I just received is not going to work so that is still an open issue awaiting cost effective solution.

For now that is all I can think of.

Len

 

[WFO-KZ]

You will have a really nice bike when done. I would love to find one, but they are really scarce around here.

One suggestion I have is to avoid screw clamps for the fuel lines unless you have special ones. If you get the right size hose that fits on with the right amount of friction, a very light duty spring clamp will work and that's all Kawi used as OEM equipment. Check Ebay and Amazon and you can get a whole kit of these clamps for very little money.

 

[LenLanetti]

You will have a really nice bike when done. I would love to find one, but they are really scarce around here.

One suggestion I have is to avoid screw clamps for the fuel lines

RE Screw Clamps for Fuel Lines...too late.

 

[LenLanetti]

Follow up picture regarding the headlight. The nut that goes with the headlight aiming screw (probably plastic) was gone and I couldn't find one on line so I fabricated something that should work from a spring clip I found in my pile of leftover parts. I basically broke off enough of the spring clip so it fits in the slot that would hold the nut. I don't know where the spring clip came from but the threads worked well with the threads on the screw.

 

[WFO-KZ]

Coming along great. No worried about the hose clamps, they don't look too bad and if they seal and you don't mind the appearance its all good.

I like to use ones like these and always keep a good supply of sizes on hand.