How we rebuilt our vintage Kawasaki KE100 motorcycle | Redline Rebuilds Explained

For your viewing pleasure and fulfillment, we’re slowing things down once again. We’ll be starting from scratch, digging into the nuts and bolts of our 1978 Kawasaki KE100 motorcycle top-end rebuild.
About 25 years ago, this vintage Japanese two-stroke bike was spared from a solemn fate at the dump. The previous owner was able to get it running again, but not well, spending the last couple of decades sputtering around in second gear at 20 mph. No more-Hagerty expert mechanic Davin Reckow came to the rescue and gave it a clean slate for the future.
Follow along as Davin and Hagerty video guy, Ben Woodworth, hash out the nitty gritty of the project in this installment of Redline Rebuilds Explained.
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[@pm375]

The KE100 was my first motorcycle and to this day, the only bike I’ve owned new. That was because my mother bought it for me on my sixteenth birthday. She spent my early teenage years denying me of my interest in motorcycles, then surprised me by altruistically giving in to my interests over her concerns for safety. I will always fondly remember her gesture. R.I.P.

[@blackisback74]

You still have it? What year?

[@vitesseguy]

As an fan of early Japanese bikes who grew up riding them, I can tell you that the carb location had VERY good reasoning. The rotary disc valve located behind the carb made for well defined and adjustable intake timing. My first street bike, when I was 16, was a Kaw A7 250 twin. It was significantly faster than my buddy's Yam 250 twin. Technology eventually produced simpler ways to make power. But in 1967, rotary valves were king!

[@talljake]

These builds and subsequent 'how we did it' videos are just fantastic. Really is my favourite thing on KZbin. Keep up the great work!

[@terrancekabir4896]

I know im asking the wrong place but does anybody know of a method to log back into an Instagram account?? I stupidly forgot the account password. I would appreciate any tips you can offer me!

[@franciscomohamed4095]

@Terrance Kabir Instablaster :)

[@terrancekabir4896]

@Francisco Mohamed thanks so much for your reply. I got to the site thru google and im waiting for the hacking stuff atm. Takes quite some time so I will reply here later when my account password hopefully is recovered.

[@terrancekabir4896]

@Francisco Mohamed It did the trick and I finally got access to my account again. Im so happy! Thanks so much, you saved my account !

[@franciscomohamed4095]

@Terrance Kabir no problem :)

[@Geordo1960]

@Hagerty...You guys are absolutely great and such integrity amongst you. Thanks so much for all of this wonderful entertainment! I really enjoy watching your work. Please keep doing these videos! I saw in the video on the Volkswagen that some viewers had suggested some of your work taking the Volkswagen engine out was cheating. Davin Recow is not and could never be a cheater; his work speaks for itself, just watch the videos!

[@starsinmyeyes]

I really enjoy these: the original videos and these BTS breakdowns. It's great to have Hagerty spotlight what you're into. That Davin is both knowledgeable and humble makes these videos particularly great for me. I always learn at least something. In this case: mineral spirits bath. The video work is fun in this one, too. Thanks Hagerty. Makes me want to work for you.

[@SuperExibo]

Guys you are great, I'm glad there is a channel like this!

[@MrCthur]

Loved watching the time lapse video. The little time lapse gimmicks were amazing. Also Davin sounds identical to Ed Friedland... and I agree about an amazing first project. My dad and I fixed a KD80 when I was in 8th grade.

[@jenntek.101]

Its amazing, almost 10,000 views in one day! I have a '74 G4TRE. It has the 2x5 speed transmission, aka "10 speed" Very cool little bike. Shift Shaft is stripped, and the fork seals need done, other than that.. Its a sweet running little light weight machine.! Thanks for the post!!!

[@essexdelapaz2994]

I found a junked 1978 KE100 back in 1997 with a seized up engine (a lot worse than you guys rebuilt). I bought it for less than $30 and took me more than 3 months to source out all new old stock factory parts (engine parts, exhaust, wiring harness, switches, handles, steps etc.) and another 4 months to fully restore the bike on my own except for the machining and the sandblast and repaint of the chassis. My project build was later featured in local news here in the Philippines. Now, I still use it for offroad, trail and leisure rides and for some quick errands. i never had a single major breakdown at all.

[@IsadoreWoW]

Love this series, doesn’t always have to be big engined or fast to be good. I say that because I have this bikes sister the kh100 in my garage (as well as a Vespa and a datsun z)

[@Jgspeedshop]

Jack White sounds like some nice stuff

[@8370DC]

This symbiosis of truly nice editing and great craftsmanship is just outright fantastic. They complement one another very well. It's a real pleasure to watch, you guys seem like genuinely nice people too. Hagerty, you're doing it right. Thanks for all the nice material, keep rocking and I'll keep watching.

[@dasutt1]

My first motorcycle rode the hell out of this same bike thank you for doing this brought back some good memories.

[@ianjones7486]

I had a 73 for my first bike. I am about to embark on rebuilding one for myself starting with a later model KE and fitting old school parts.

[@tyleryoung6577]

Nice video, been waiting a long time to see someone take the time and effort to make a video like this on the ke100.

[@paulstan9828]

Always so interesting and fun. This one brought back memories of having a bike in the early 70’s.

[@stephenpaynter515]

Educational & entertaining - what more can you ask for?! Keep up the great work, lads, please.

[@ROWINZILLA]

9:11 WOW that Weisco is something special

[@wickpoker]

Outstanding! I hardly ever thumbs up, let alone comment on videos, but this video and the shorter build video were fantastic. I’ll share with friends. Thanks!

[@jason5584]

I love these commentated videos! I'd love to see a LS1 rebuild

[@nathancatalano3301]

I'll be riding my recently rebuilt 1977 Trail 70 around Petoskey, Michigan in a few weeks!

[@calebsextro3418]

I love these videos they are absolutely fantastic!!! Thank you for making them.

[@crwdavis]

Really appreciate this video, just beginning my own 1980 KD80M tear down and complete rebuild.

[@KevinMn1]

Great project and love the commentary

[@hugieflhr03]

Awesome videos!!! How much bigger did you have to go on the bore?

[@trevorwinnie4280]

Only thing this needs is part guides and references too them

[@DoubleOSeven007]

Loving the Darth & Davin sharing skool dayz :)

[@ColtSSR]

Great video, it reminds me of my '73 MT250, sounds the same too

[@robertatwood2503]

these are the best videos y'all are so awesome thanks

[@ANILTV82]

Now I can work on my Yamaha 2 Rx100 thanks!

[@MrGTO-ze7vb]

Easy rebuild..!! I miss my old Kawasaki A7SS 350 twin .. rotary disc valving. Purchased in San Jose CA for $200. in 1981 and drove it on the road for 5,000+ miles

[@wheelerdealer2105]

Good job guys.Couple of things I would add for anyone doing one of these. There are very few of these in the condition yours was . All the ones I've done in recent years the LH main bearing needs replacing. You should be replacing the seals anyway. Pull the LH seal Before you split the cases, clean the shaft and the grove where the shaft and bearing join very good to prevent scratching the shaft when it comes apart. Check for a good fit of the bearing race and shaft, if the inner race can spin on the shaft you need a new LH crank half. When you install the new seal see that it does not cover any of the oil hole (I notch the seal a bit to clear it). Most parts for these engines are still available from Kawasaki and the Fort Smith, AR dealer. Tom W

[@Jimmy_Watt]

Thanks for the great video. I have a 1998 model that will need an extensive go over soon.

[@spymaine89]

wonderful . great instructional.

[@CerberusTNC]

If I may ask, how you suggest getting parts for a bike like this? I have a similar bike and I have been trying to find the parts to rebuild it for a couple years now, and I can't find the right parts.

[@owen368]

Nice rebuild glad it was just back to stock hate when people "modify" an nice old bike to be something it's not regards from UK oj

[@TheAlpineProject]

The rotary disc (or rotary valve) can be opened up to essentially allow more fuel timing. A clever fella down under even made a variable version for a Kawi Bighorn. Also if the crank seals are original, they're likely letting air get sucked in and causing the bike to run lean. 2 stroke preoiler systems often get blamed for what's really an engine leaking vacuum. Rigging up a vacuum tester and finding leaks is well worth your time if you haven't, otherwise you might end up doing another top end rebuild. Regardless though, nice video.

[@CWS1963]

Nice comment, as an ex Kawasaki wrench from the late 70s to 90s I was saying the exact same thing watching this. That piston died from being lean, and it's rarely the injection system that is the culprit. Cant count the number of Kaw 2 strokes we saw with the pumps disconnected.

[@billbright1755]

Kawasaki quality. 😊

[@saqibansari1811]

Very good

[@peterholthoffman]

Nice video with a special connection for me! I learned to ride in 1972 on a yellow 1972 G-5 100 which was the precursor to this one. The official top speed was 66 mph but the particular instance I rode could hit 80, as clocked by a car travelling alongside. Of course, we only weighed ~125# at the time so it wasn't overloaded and I can't say the road was 100% flat; there might have been a slight grade to it (but not much). The great thing about it was that it was just about indestructible! At least three 15 year-olds learned to ride on it, from scratch and we rode the daylights out of it. It was jumped over 70' horizontally and 10' vertically (on the same jump) which cracked the front hub from side to side. It still rolled fine but you wondered when it was going to let go completely! We also sheared the foot pegs off with hard landings. Unfortunately, it was eventually stolen and that was the end of that. I hope some day to have a collection of 1972 Kawasaki trail bikes from the G-4 to the F-9 (it's weird that the 350 was F-9 but the 250 was F-11!) to go with my collection of Honda Motosports. The enduros of that time are what the motorcycle industry needs today to save it. If you don't sell something a 12 year-old can dream about and a 15 year-old can save up for, you're not going to get life-time riders. Coke and Pepsi understand the importance of those years. You also need a seat height that works for a kid with a 26" inseam. I see others have commented about the rotary valve input explaining the carb position so I'll skip that.

[@peterholthoffman]

Btw, you mentioned have trouble getting to neutral? Was that transmission still N,1,2,3,4,5 (neutral at the bottom) or had it gone to the current standard of 1N2,3,4,5?

[@m1dntlkgud]

Exact year and model mine was that I rebuilt with my dad. It's kinda a pita to tune the carb under the cover.

[@amandawatson5931]

One o...ok, my favourite rebuild.

[@nicolasmilovic2300]

Great video!!! Do you know the main difference among the ke100 and kv100?? Im just about to start a project with a kv100 1975...

[@chrishastings2665]

Got my 1970 Trail 90 for $125. and all it needed was a battery and tune up. ride it all the time.

[@ColtSSR]

Chris Hastings one the early yellow ones?

[@chrishastings2665]

Elo bob Dwarka mines red. I do like the yellow though.

[@JeanRoi]

I would love to see the wiring done. I'm wanting to wire up a 1987 kd980, Kawasaki

[@bobbychilders7233]

Guys, I have that exact bike and I wanted to clean it up and see about getting it restarted. Could you list the places that you purchased replacement parts?

[@ColtSSR]

Id like see more old dirtbikes

[@CanadaBud23]

Wondering if you guys do the ol'Jeep 4.0L, maybe Renix? I know it's simple and not much to see but I'd like to see a video with your style to it!

[@anthonytenaglia3473]

I have my first dirt bike I just got back today pulled out of my Neighbors shed after 14 years a 1994 KE 100 and Ayame going to start the rebuild process going to need to find one of those batteries and possibly a gasket kit any recommendations on where to look and I will order one of those books for the torque specs

[@tyleryoung6577]

How did you guys clean the old paint and rust off the jug and head?

[@graciehunt9405]

The ring gap has to pointing in different positions to make compression

[@LaxDave9999]

Hi, I enjoyed the video. You all seemed mystified as to why the carb is on the side under the side case? I am pretty sure that this is a rotary valve intake system. At least my trail boss 100 was, and I thought most all of the small displacement bikes of this era were? I could well be wrong, as I am not expert. But, also, I thought I saw the cover for the rotary valve once you all got the rest of the side cover off? You all did not take it apart, however. With the rotary valve, it was easier for Kawasaki to just mount the carb on the side, versus doing what can am would do later which was to mount the carb behind the cylinder with a intake runner down to the rotary valve. Great shows, thanks again.

[@saksittichompoo3583]

My first motorbike was a Yamaha YG5 with 80cc displacement. It used same rotary valve technology. It was pretty popular tech for 2 strokes-engine back then. The constant valve opening made the engine to have good engine power at certain engine speed.

[@ericmiller9132]

Yes, this is a rotary valve 2 cycle or 2 stroke engine, depending on your preference of description. During the late 1960's through the 1970's, manufactures used all types of induction on their trail bikes, with reed valve intake becoming the most popular due to it's simplicity and cost. Kawasaki stuck with the rotary intake system on the KE 100 through its lifespan. The rotary valve system allows for the widest power spread across the RPM range but it is more complex. Reed valve induction is really no more complex that piston port induction but allows for more low speed engine torque, so a nice happy medium for the cost. Can-am (Rotax) engines of the 1970's were always ranked very high in usable horsepower delivery in magazine tests and usually delivered the highest HP output on the Dyno as well.

[@ganeshandhanasekaran3510]

Recommend good tool kit for bike restoration for beginners

[@jesseallen8246]

Hi, I’m doing a build on a 75 sportster and I’m wanting to do a build similar to yours. Please let me know where you got the rims, tires and rear fender, thanks.

[@psyhojolo6327]

love thet video gimie more,plese meake rewue off it;)

[@youtruckrek5121]

cool

[@crwdavis]

@12:30 you put a gasket on the clutch cover, do you mind me asking where you got a gasket for this case? My KD80 has the identical case, is my understanding, but I am having difficulties finding gaskets, especially for the halves.

[@blackisback74]

Why not just use ATV gasket silicone?

[@pabitrikalita3940]

I had to rebuild my Kawasaki 2 stroke but the problem which I encountered was that it has no power at the top end, so what could be the solution

[@amuridesu]

guys, can you rebuilt rotary engine? i love rotary

[@briangoodhuejr5710]

Idk if you guys do requests, but could you guys try to do the Ford 6.8L V10 from Ford

[@sukakdamai3826]

You need to try rebuild some yamaha rx king series it's also a nice bike..

[@jaycalgary7]

Did they even catch on that it is rotary valve?

[@edwardsabo8368]

So how much did it cost to rebuild this beast?

[@bradyperkins565]

Dear hagertv. I hope you see this message. I recently purchased a 1973 Kawasaki f7 175cc enduro. I have looked all over for a video on the internet. Any chance you guys can do one to help a brother out?

[@stephenclark5812]

I am surprised that you guys don't know why the carburetor is on the side of the engine. It is a rotary valve two stroke, so the carb basically had to be mounted that way.

[@niltonsantos7084]

How can I can contact you about a possible automotive grave yard of older cars in the New England Area?

[@carterdailey5253]

Hey guys I am currently working on my own 1977 KE100 as well. I am struggling to figure out the electrical. Any tips?

[@xxjusxstarxx]

Just completely rip out and start new, so much easier

[@xxjusxstarxx]

Just take pictures of wire plugs and stuff before hand so you can reference.

[@thesw313tspot8]

did you have to resleeve?

[@kentketola1921]

I need a motor for one of these

[@overlandperformance338]

I Got a 1979 CT70 on craigslist for a few hundred so yes you can buy one for cheap but it has to be beat up

[@LebonezLive]

my 1972 kawasaki g5 (ke100 predecessor) is oil injected so definitely doesn't seem to be ahead of its time in 1978

[@theodoreberbach9562]

Hi Hagerty team if you could reply to me it's be awesome. So I recently found a ke100 for 250 bucks, doesn't run, should I buy it and attemp to fix it at home as a starter learner to rebuilding motor? I don't have any prior knowledge to rebuild so I want to buy some cheap thing for a project

[@Hagerty]

Theodor - For $250 is sounds like a great price to start an adventure, learn a few things, and end up with something fun in the end. Give it a go!

[@asfia82]

wish they rebuild my old modenas kriss 100 (malaysia) to new

[@Welcometofacsistube]

Good. At least it’s not another LS swapped video

[@JackDaniels-ok2qv]

Please rebuild a ford 300 I6!!! The most durable gasoline engine ford ever made!!

[@danielcheng5070]

I'll rebuild my two stroke KTM according to this standard!!! lol

[@NowAndyPlays]

I had a piston wrist pin walk out on me once...

[@ddcraun]

I think you guys need an old school shifty Vespa....

[@ronmurdock8897]

O have a 92 ke 100 I’m trying to get running but I need info and help if anyone has any input lmk

[@gunawanbudiarto898]

Twin H engine please

[@hyattbusbey3563]

Weird to see a 2smoke with the chain on the right.

[@evilsadvocate]

you guys did not use the right fuel line, and skipped the fuel line through right side cover grommett. if the right side cover isnt air tight the air filter does nothing.

[@firfahmanzuraidi3630]

Hi to all that eat restoration for breakfast . I'm need some clarification from you guys . I'm still new in this restoration thing. is it really possible to machine the 2 stroke engine block to fit a new size piston?. from what I'm inform that 2 stroke engine block have a thin coating on block wall (molybdenum) I guess, that made on the block. so than if you machine out that thin coating and block itself to resize your block to fit new piston, the block won't be good and will not last longer. is it true ? . any reply I be appreciated. just want to improve myself to be better.

[@blackisback74]

You would have to get the cylinder recoated after it's bored out

[@asitnaik9818]

Build more 2stroke bikes.....>>>

[@MuzyTR]

TR ilk

[@Douknowgregg]

It's not a dirt bike. It's on par to a klr 65o by today's standards.

[@demonic4774]

contact the KZbinr Mustie 1 he is or has buy now doing a Honda Trail 90 restore and will sell it he restore's or repair's and yard sales all his builds

[@pablosinatra3034]

Do Redline Rebuild the dodge flathead six

[@gunawanbudiarto898]

Twin H engine

[@MrBwalendy]

Ok, this is a junk bike. It should have never been rebuilt. There are hundreds of bike canditates that are worthy of working on. Such a silly exercise. It was nothing when it was new and is useless today. Stupid is as stupid does.

[@ericmiller9132]

Watching the video they explained the reason for the "rebuild" was basically it was a bike that was just laying around, so no real expense. Since most people have never seen a rotary valve 2 stroke, it provides some educational value. Would have been more educational if they would have performed a full rebuild, split the cases and such. Old dried up crank seals can cause a lot of tuning problems, but are offend overlooked. As for better candidates, anything popular already has 100+ videos. Don't be too hateful, these bikes are like fat chicks, they're fun to ride until your friends see you with them! :)