Restore Kawasaki

#11: Assembly 2

/in /by

Project Kawasaki Drifter / Episode 11

#11: Assembly 2

The finish line in sight—tank, fairing, and final details


EPISODE
11 of 12

DIFFICULTY
Medium

TIME REQUIRED
1 day

Video Tutorial

Work Steps:

1

Body parts

The tank, side covers, and fenders are installed. Use new rubber grommets!

2

Electrics

Connect all lights, turn signals, and instruments. Check all functions.

3

Final checks

Check that all screws are tightened correctly. Test brakes and throttle response.

4

First start

Fill with fresh oil and fuel. The big moment: first engine start!

Almost There!

The finish line is in sight! The painted parts are finally mounted. The Kawasaki slowly takes shape and looks better than ever.

Pro Tip

Use microfiber cloths when handling painted parts. Fingerprints show immediately on fresh paint!

Final assembly

Fluids are filled
Fluids are filled
Engine oil
Engine oil
Brake fluid
Brake fluid
Coolant
Coolant
Gear oil
Gear oil
Gasoline
Gasoline
All fluids checked
All fluids checked
Final checks
Final checks
Test run
Test run
Ready to start
Ready to start
Paint frame with paint spray

#07: Paint the frame

/in /by

Project Kawasaki Drifter / Episode 07

#07: Paint the frame

The centerpiece—the frame gets a fresh coat of paint


EPISODE
7 of 12

DIFFICULTY
Medium to Hard

TIME REQUIRED
2-3 days

Video Tutorial

Recommended SET

Frame Painting SET

Go to Shop →

Work Steps:

1

Rust removal

Remove loose rust from the entire frame using a wire brush and sandpaper.

2

Rust treatment

Apply rust converter to all affected areas. Allow to work for at least 24 hours.

3

Priming

After drying (min. 24h), spray with 2K primer in 2 coats.

4

Top coat

Apply frame paint in 2-3 thin coats. Use 2K paint for durability.

The Goal

The frame is the backbone of every motorcycle. A perfect paint job not only looks great but also provides lasting rust protection.

Pro Tip

Hang the frame so you can reach all areas easily. Use a rotating hook for even coverage.

Frame painting

The frame is primed
The frame is primed
2K paint structure scheme
2K paint structure scheme
paint with dasAuto paint spray

#04: Paint body parts

/in /by

Project Kawasaki Drifter / Episode 04

#04: Paint body parts

Finally, paint! The tank and side covers get their new paint job.


EPISODE
4 of 12

DIFFICULTY
Medium to Hard

TIME REQUIRED
1-2 days

Video Tutorial

Recommended SET

Base Coat & 2K Clear Coat SET

Go to Shop →

Work Steps:

1

Degreasing

Wipe again with silicone remover shortly before painting. No fingerprints on the surface!

2

Base Coat

Apply base coat in 2-3 thin layers. Allow to flash off for 5-10 minutes between layers.

3

Clear Coat

After 20-30 minutes, spray 2K clear coat in 2-3 layers. This adds shine and protects the base coat.

4

Drying

Allow to dry dust-free for at least 24 hours. At room temperature, no direct sunlight.

Attention

A dust-free environment is essential! Wet the floor and close the garage door. Every speck of dust will be visible in the paint later.

The Goal

Now it’s getting exciting! The prepared parts are getting their new paint job. The tank and side covers are being coated with high-quality base coat and clear coat.

Pro Tip

Before use, warm spray cans in warm water (not hot!) to approx. 25°C. The paint will then spray more finely and evenly.

2-Coat Paint Finish

2-coat paint finish is applied
2-coat paint finish is applied

Restore Kawasaki

#03: Repair previous damage 2

/in /by

Project Kawasaki Drifter / Episode 03

#03: Repair previous damage 2

The fine work—sanding, filling, and final preparation


EPISODE
3 of 12

DIFFICULTY
Medium

TIME REQUIRED
1-2 days

Video Tutorial

Recommended SET

Filler & Primer SET

Go to Shop →

Work Steps:

1

Fine sanding

Smooth the filled areas perfectly with 320 to 600 grit sandpaper. Always sand in one direction!

2

Apply filler

Spray on 2K filler in 2-3 coats. It fills small pores and creates a perfect base for the paint.

3

Control sanding

After drying, sand the filler with 600 to 800 grit sandpaper. Any remaining unevenness will now become apparent.

4

Rework

Make minor repairs with spray filler, then fill and sand again until the surface is perfect.

The Challenge

After rough filling, it’s time for the fine work. The surfaces must be perfectly prepared—every little bump will be visible later in the paintwork!

Pro Tip

Check the surface in raking light! Shine a handheld lamp over the side of the part—this will reveal even the smallest irregularities.

Tank Repair

The tank before repair
The tank before repair
Filler is applied
Filler is applied