Project bike rebuild.

Hi. I have just bought a Kawasaki Project bike. I am told that it is a Kawasaki Serpico 150 SSR. The Frame number is KG125A. Can anyone tell me how to establish exactly what model and year it is and where I can find a workshop manual online as I would like to rebuild it from scratch.

The model is based on your engine numbers, the year of manufacture can be refer to registration card.

KG150 in malaysia is referred as KRZ150, and KS150 is belong to serpico 150.


In my opinion you can get the manual book from thailand as serpico mainly comes from there. To find it online is might be difficult i think. You might need to spend some time go by your self to any distributor in thai or you can ask for help from friend there.

However, the basic for the engine you can refer to new model KR150F/K and for the wiring and chassis KS150A..

Thank you for your response. I will see how I progress. I am in Africa and these things are always difficult.

Project nearly done now. Bike runs like a dream. New coil, cdi, clutch serviced, oil leaks sealed, bit of radiator sealer, new sprockets, chain, and a new spray job.

That thing looks sweet man!!! How does she run?

She runs like a dream. Nice and quick. I am onto my next project bike, a Kazuma 150 tri port. It was in an accident. I have rebuilt all the bodywork (glued it all back together and re-enforced the breaks with resin preimpregnated fiberglass ( Luxor Fibre Filler - Great stuff that! ) on the inside, and body filler on the outside. What I do is I cut out the broken fairing piece from a piece of firm card paper, then stick it to the fairing. Then I build up the inside with Fibre Filler, let set, tear off the paper, sand away, put body filler on the outside and sand smooth again on the outside and the inside.

Bodywork finished. Now it is on to spray.





She will be pearl white and chrome when done. A few little stickers here and there.

dAMM BRO GOOD ON YOU AND YOUR BIKE MAN! KEEP THE PICS COMING MAN THIS IS GOOD STUFF!!!
I WISH THERE WERE MORE PEOPLE WHO DID STUFF LIKE THIS ROUND ME! IN THE STATES I WAS IN A CAR GROUP AND WE DID STUFF LIKE THIS ALL THE TIME! TURBO, LOWERING, CHIPS, WIRING...

HAVE YOU TRIED FUEL INJECTION ON 2 STROKE? THEY SELL KITS ON EBAY! JUST HAVE TO ADD MASS AIR SENSOR, AIR TEMP SENSOR, EXHAUST GAS SENSOR... NEW THROTTLE BODY, LIKE CARB BUT INJECTOR WITH POSITION SENSOR AND COMPUTER.... BUT I DONT KNOW IF IT CAN SUPPORT WHEN THE KIPPS OPENS, I THINK IT WOULD BE OKAY!

ANYWAYS JUST A THOUGHT... THEESE BIKES ARE CHEAP TO WORK ON AND MODIFY, THATS WHY I GOT ONE MYSELF, I LOVE IT!!!

GOOD LUCK!

KRISH.
SABAH, MALAYSIA

Yes, quite right, these bikes are nice and cheap to work on. Thanks for the kind words. This rebuild has cost me around $200 so far, with maybe another $ 100 to go. All in all, around $300 for a total floor up rebuild. That gives me around $700 profit when I sell it on. Total time around 5 days, working weekends only over a 1 month period.

I hear what you say about the upgrades, but I get the best prices restoring it to stock standard.

Cheerz mates

hey buddy, keep them pictures coming man!!!

Im taking my bike in to port the exhaust and also the kips outlets, (is that what you guys call it)?
cleaning the head piston...etc
ill document it the best i can and post it!

right now im riding a 2010 150RR, i just got a AHM SPR1 Racing exhaust and i took out my filter and made the inlet at the airbox bigger,
just set the carb, she runs like a champ after numerous hours of labor, using Petronas 2sx 2t and shell 10w 40 lube. NGK B8ES. 428 roller chain, 15 front & 42 Rear sprocket!

Ill post some pics!

Take it easy man!!!

Did some mre work on the Kazuma today. Yes, I know its not a KIPS, but they are very similar.

Well that's my Saturday project moving along nicely. Restoring my lil boy-racer. Got all the chrome bitties back. Chromed all the metalwork, including the rims. So, aside from the frame, she be all nice and shiny. Some would find it a bit too much flash, but as a Friday night fun bike she is going to pop. I did the spray painting myself. A nice slightly off white pearl glitter and chrome finish. Some kid is gonna have all sorts of fun with his Christmas present.. And so, the rebuild continues. Tucked away all the wiring so that she is nice and clean. Next Saturday all the bodywork goes on and then I guess she be done. What did you guys do with your Saturday? Oh yes, we also sneaked in a barbeque / grill and some wine and beer drinking for the sanding team.










Apologies for the poor quality pix, but I will use a better camera next time.

Bro,

i just got my bike ported and polished, the low end is gone but the top end is ridiculous!!! it needs to be jetted, the pilot is at 22.5, it needs to be at 30, so im taking it in tonight! saturday's is chill with my little baby girl man, but ive still got the heart of a racer inside...

Dude ill post some pictures of the porting process and also pics of my bike...

btw, i used to ride a Ducati monster M900 1994 model, carb... its a bad boy, i think u can pics thoose up for cheap nowdays! its a fantastic muscle bike, gets loads of attention and sounds like thunder.
common prob's is carb dirty, and loss of compression, worn clutch and worn clutch hydraulic seal... other than that! BEAST! 0-170kmh in 5 seconds!!! NASTY!!!

downside, very heavy feeling, transitioning left to right while riding... cant gas during slow corners, have to use clutch, too torque'y... Drinks petroll like a horse/camel!!!

anyways bro here in Sabah Malaysia, its not like Kuala Lumpur Malaysia, not many Long Highways, so im on big sprocket, 42 rear, 15 up front, 428 chain... thinking of going 16 infront! Mad pickup and mid range!

thats is bro, talk to you soon... be easy and have fun on the bbq!!!

Krish C.

Looking forward to it mate.

Moving forward with my weekend bike rebuild, here are some of the latest pix. How do you like the paint. Glitter Pearl white with blue and gold blended tinits ... Some angles white, some angles white glitter, some angles light blue, and some light gold. Cool huh? . Just some wiring and stuff left. I think next weekend should see me done. Bodywork and other stuff, rebuilt from the ground up. Some parts bought new. All existing chrome re-polished. All metalwork sandblasted and powder-coated in plastic chrome finish. Exhaust repainted in black exhaust paint.

That makes the basic color scheme Pearl white, Matt black and Chrome. I think the contrast pops quite nicely.











Bike was in a crash, so I scored the wreck.

All body panels rebuilt by hand with Pratleys clear, Fibre re-enforced resin and body filler, and lots of sand paper. Material, resin and filler cost +- $75.00

4 layers of paint , Undercoat, Base white, Transparent pearl effect glitter coat with tones, 4 layers of spray on resin clear coat +- $75

Chrome plastic powder coating of all painted metal parts including rims. $90.00

Removal and replacement of tyres $25.00

Aluminium welding of cracked aluminium parts. $30.00

Purchased spares (front) $140.00

All m6 (Body) screws replaced with stainless steel allen key dome head screws ... $30.00

Contracted labour $100.00

Cash outlay $565.00

Own labour +- 24 days of weekend (saturday afternoon) tinkering over 6 months .... Priceless.... heheh.

Brooo!!!

That baby looks clean man! the paint looks good and the engine and all the metal is gleaming from what i can see... And that seat looks confy, touring style... You did Weell My Frend!!! Very well!!! Good For you!!! wish you were living here, i could buy that from you and keep it as a weekend rider only...

Krish C.

Yes, she is gonna be better than factory new when she is done. Polished up, and chromed and powder-coated, and a bit of subtle customizing, but she will still technically be stock factory standard. Thats what brings in the money, ... Original is a good investment. Next week its finals on the electricals, indicators and brake lights and stuff and then she will be ready for sale. Got my eye on the next one so I am keen to get her out. Someone will be buying a solid bike. The motor only has 4000 KM on the clock and runs sweet. I would keep her myself but our club rule is 500cc+

I love the idea of all stock!!! 500cc+ thats a great rule! so what kinda bike do you ride?

And is it a 2 stroke 500cc gp bike of the old days?

i saw a replica on ebay, OMG it was crazy!!! when i go back to the states im going to get me one of thoose! i cant imagine the power band when the Power valve opens!!! wayne rayne and the old school riders were mad men!!!

take care buddy!

krish C

Well, just about done now. A few little bits and pieces ... Mirrors, new battery, etc.  and then I can go for a test drive. Jan I am taking her in for a kikass custom spray job. Nothing too wild, just a bot of character.








I am thinking of these kind of graphics.

Wow super nice graphics man! Im kinda bored with mine already! im waiting to do the engine upgrade to 200 cc. 68mm cylinder head and piston kit. it was supposed to be done this month but i got xmas presents instead and treated myself to some new clothes. Always nice... hehehe Hey buddy merry christmas and happy new year man! listen why why dont u give me ur e-mail and i will send u some pix. its kinda weird here cause i have to host it. anyways take care...

Krish C.
krishchandran2015@gmail.com