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Restore Kawasaki

#08: Assembly 1

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Project Kawasaki Drifter / Episode 08

#08: Assembly 1

Finally! The frame and engine are reunited


EPISODE
8 of 12

DIFFICULTY
Medium

TIME REQUIRED
1 day

Video Tutorial

Work Steps:

1

Engine installation

Carefully insert the engine into the frame. Check the engine mounts!

2

Wheel mounting

Install front and rear wheels. Check bearing play and brake discs.

3

Connections

Brake lines, fuel lines, and electrical systems are connected.

4

Check

Check all connections for leaks and proper fit.

The Goal

The moment we’ve been waiting for! After all the painting work, the motorcycle slowly comes back together. Engine and frame are finally reunited.

Pro Tip

Use new gaskets and seals everywhere. Old rubber parts can crack and cause leaks.

The rebuilding begins

Engine is installed
Engine is installed
Frame with engine
Frame with engine
Front wheel mounted
Front wheel mounted
Tank attached
Tank attached
Electrics are installed
Electrics are installed
Almost finished
Almost finished
The result takes shape
The result takes shape
Paint frame with paint spray

#07: Paint the frame

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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 pulls up

#05: Paint pulls up

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Project Kawasaki Drifter / Episode 05

#05: Paint cures

Pure excitement—the fresh paint develops its full shine


EPISODE
5 of 12

DIFFICULTY
Easy

TIME REQUIRED
Wait!

Video Tutorial

The Magical Moment

One of the best moments in any paint job: the clear coat cures! Within minutes, the matte surface transforms into a high-gloss mirror finish.

Now it’s time to be patient and not touch anything!

What Happens Now:

1

Flash-off (0-30 min)

The solvents evaporate. The paint slowly becomes duller, then begins to shine.

2

Surface Dry (30 min – 4h)

The paint is dust-dry but still soft. Caution—do not touch!

3

Full Cure (24-48h)

The paint hardens completely. Only then can polishing begin.

Pro Tip

2K paints cure chemically—the warmer it is, the faster they cure. At temperatures below 15°C, it takes significantly longer. An ideal room temperature is 20–25°C.

Primer and Filler

First primer coat
First primer coat
Filler is applied
Filler is applied
Finished substrate
Finished substrate

Restore Kawasaki

#03: Repair previous damage 2

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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

Kawasaki Drifter

#01: Disassemble completely

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Project Kawasaki Drifter / Episode 01

▶️️ #01: Disassemble completely

The beginning of a big project – the Kawasaki Drifter is completely disassembled

▶️
Episode
1 of 12
▶️
Difficulty
Medium
⏱️
Time Required
1-2 days

Video Tutorial

▶️ Recommended SET

Complete Paint Set for Motorcycles

Go to Shop →

Work Steps:

1

Documentation

Before disassembly: Take photos! Photograph every screw, every cable, every connection. This helps enormously later during reassembly.

3

Electrics

Disconnect the battery, then systematically disconnect all electrical connections. Mark the plugs!

4

Engine & Gearbox

The engine is removed and stored separately. Drain the oil first!

The Project

The Kawasaki VN800 Drifter – a real gem in Indian style. After many years on the road, it needs a complete restoration.

In this episode the big adventure begins: Everything has to come off! Tank, fairings, engine, wheels – piece by piece the machine is disassembled.

2

Tank & Fairings

First, the tank and all fairing parts come off. Store screws and small parts in labeled bags.

Pro Tip

Use magnetic screw trays and label everything! A smartphone video of the disassembly can be worth gold during reassembly.

Damaged Gearbox & Engine Repair

The destroyed gearbox
The destroyed gearbox
The broken spacer ring - the cause of the damage
The broken spacer ring – the cause of the damage
New gaskets for the rebuild
New gaskets for the rebuild
Fully assembled engine
Fully assembled engine