Monday, October 10, 2011

Adios Zundapp

Due to other projects coming to the forefront the Zundapp has gone to a new owner who hopefully will bring it back to its' former condition. After weighing in the costs of bringing it back to life, I found that I would rather work on BMW's, basically due to the availability and reasonable costs of parts. So I hope the Zundapp will be in good hands and not be pieced out.

Wednesday, October 5, 2011

Going, Going, Gone....

I'll be damned but the Zundapp hit my reserve price on EBay this evening. I have mixed emotions about selling it but I have a hard time justifying the proper restoration costs needed to bring it back to life.
I'm much more comfortable working on my lower budget BMW projects since parts are found much easier and cheaper.

Sunday, October 2, 2011

Reserve met?

I had a weak moment last night and decided to list the KS601 on EBay. I have an amount invested so far and if I can make back my investment, plus my seller fees it will go to a new owner.
The amount of money required to properly restore this machine is above what I can spend. My alternative is to modify the bike to accept a BMW engine. The conversion option would take the original value away from the bike but it would be more practical for daily use.
The bidding quickly went up to over $1600.00 in the first 24 hours. There may be a serious collector out there with deeper pockets than mine who will properly restore the machine.
My R100S sidecar rig needs work...rear main seal, possibly a clutch due to oil from the rear main seal, cylinder base gaskets and a new timing chain. Right now I have 4 projects in hand and the Zundapp will be the most costly. So we'll see how the auction goes. If my reserve isn't met, I'll continue on with the work at a slow pace no doubt.

Monday, September 5, 2011

Stuck Pistons, Volume 2

Before spending 12 weeks in Arkansas this summer I filled the cylinders with Marvel Mystery Oil and let them sit. A week ago I pulled the heads and related pieces off in an attempt to "free" the pistons in the bores. I found that a lot of the oil had seeped out so they were no longer full of oil. I worked the transmission into high (4th) gear and rocked the rear wheel in an attempt to move the pistons but to no avail. I then used a wood dowel and gave each piston head a little "wack" to hopefully shock the rings free but again to no avail.

I reassembled the engine top end and left out the push rods this time to assure no valve openings to loose more oil. I filled them to the brim with Mystery oil through the spark plugs and sealed her up for another soaking session.





This time I removed the carbs, air tubes, exhaust system and all related parts to speed up the tear down next time. I labeled everything and stored the pieces in a sealed container.


I've been monitering oil loss this time and things are holding well. I added maybe a couple of ounces to the left side cylinder today and the right jug is still full.


The Zundapp Pistons each have 5 piston rings on them so I have been told so there are more rings / rust holding onto the cylinder walls. Hopefully a few weeks of soaking will free things up.



The other day I removed the hacked up shifter linkage which was on the bike and installed a nice original ($80.00) linkage assembly. This "new" linkage has a bit of surface rust to be removed but it is in nice condition. I also found a reproduction headlight ring on EBay a while back. I haven't installed it but it appears identical to the beat up, dented original on the bike now.





Saturday, April 30, 2011

Zundapp Factory Photos - mechanical

An early Zundapp Advertisement for the "Autobahn" capable KS500



Engine "ghost" photo. The Cam Gear & Oil Pump Gear are a fiber type material. A well known Zundapp guru tells me these gears last quite a long time. He has seen ones from the 30's still in good usable order.

The "Bing" carbs. Similar to those used on BMW's and other motorcycles.


Rear "ghost" view of KS601 Engine




The chain assembly in the transmission. These are very robust and long lasting.



Front fork assembly




Plunger rear suspension. Some upgrades were available for these back in the day.



Zundapp Final Drive Assembly



Another front end photo.



Zundapp Coversion?

I got this photo of a Corvair Converted Zundapp KS601 from the ADV site. I think it still utilized the original Zundapp transmission so that somewhat attests to the strength of the transmissions.

The frame was stretched out quite a bit to stuff the 6 cylinder boxer motor in.


The Zundapp Transmission chain configuration. I have a friend who had ridden one years ago and he said it felt like a rubber band. The manual shifter engages a system which automatically shifts the gears, The lever does not directly link to the gear set.



If for some chance my Zundapp engine was completely shot I might entertain the thought of a BMW engine coversion. I have the 1982 R65 which could be a potential donor but.......I'd hate to destroy one of the few remaining KS601's. If I did do a conversion it would have to be reversable to the original drive train.


Monday, April 25, 2011

Let the "bleed" begin.....Zundapp Style

The ultimate Zundapp...in my opinion. The Zundapp KS800. Four cylinder flathead engine. Manual hand shift. An Art Deco work of art.



The KS600 Hand shift. This bike has the same foot lever / linkage as the KS601 but also utilized a hand shifter along the tank.




While the engine cylinders soak I've been scrounging up a few misc. parts via the Internet.



Found this 50's NOS 6 Volt horn over in Greece for cheap. Not a KS601 original but the price sure was right. It is around 3.5" diameter so should fit where the original lived. I'll need to bury it in the backyard for a few months so it matches the rest of the bike.



My gas cap is dented up pretty good....this original KS cap has a few less dents. It was a $5.00 purchase.




My KS has one "ball tip" lever and one short spear type lever. I bought the shorter of the two here so I have a matching duo.







Someone in the past has hacked up my linkage. It still functions but the proper pins were missing and the linkage pieces had been split. This replacement linkage is the most expensive item on the page.....but this will get things back in order. The KS600 had both a foot shift and a hand shift lever. They ran a rod from the right side linkage up to a tank side hand lever. Maybe I'll copy that design and rig up a hand lever. I think that would be cool.



One proper Bing carb screw to replace a BMW idle screw which was improperly fitted.




These are the proper pins needed to affix the new shifter linkages.




I'm missing the front upper fender brace. This brace comes with a nasty old "bobbed" fender. I'll remove the brace and refit it to my fender. I do have some old school aluminum fender struts but preferred the original ones.






This is a clutch linkage tensioning spring. My clutch / brake cables are shot. I found an outfit that supplies cable kits which allow the builder to manufacturer their own cables...I'll give it a shot.