After 5 years on smaller motorcycles, I finally purchased my first ‘Big Bike’! It needed a little work to get it road worthy but as with all my projects, I am keen to fix it! Currently I’m mid-way through the repairs but I’ve finished the major jobs and given it a service. I have also booked my ‘A2’ tests for december and can’t wait to get on the road with it!
The gallery below shows the repair work I’ve done to the bike so far. I intend to vinyl wrap the whole bike to cover the repaired left fairing as this was in very poor condition when I bought it.
Here it is before I started work, noting that this is the good side! 
The exhaust looks almost like factory now! 
The finished product after using hydrochloric acid to remove oxidation and a soft wire wheel to give a satin finish. 
After welding and grinding. Note that the pitting is likely due to lack of any exhaust clamp when i purchased the bike which allowed water to make its way between the grapgite gasket and stainless steel. 
I placed a sleeve within the exhaust to minimise the amount of weld building up on the inside and reduce the likelyhood of blow-through. 
Cracks in one of the fairings were repaired by plastic welding, using ABS 3D print filament as ‘weld rod’. This panel had previously had a very poor paint repair job and so I wasn’t worried about ruining the paint on it and my intention is to vinyl wrap the whole bike in Kawasaki green!