DKW KS WH

The cylinder is removed from the engine. The surface shows signs of corrosion. The indentation is small but clearly worn out.

A lot of carbon deposit was here. This engine was used with a bad oil. The cylinder ducts were plugged. One of exhaust ducts was completely blocked.

Carbon deposit and settlements have been removed. There was a lot of dust here, so the cylinder has been pressure-washed, dried and painted.

The piston was seized. The rings got stuck in grooves.

Piston has been cleaned. The lowest ring is to be replaced, at the front side it got "baked" into its groove.

If this piston is meant to be in use again, it would be best to replace all rings. The bolt in the piston is a bit too loose.

The clutch shaft shows signs of damage.

The crankcase is damaged, too, at the point where the ring is inserted to hold the shaft bearing.

The shaft was renovated some time ago. Connecting rod end without clearance. Shaft pins were polished. Oversized rolls in the bearings (13x6,07 + 2x 5,75). In one bearing there are signs of corrosion, to be removed.

All parts to be cleaned and checked.

The left crankcase was fixed once. It was welded where the ring is inserted. There are visible signs of the impact force. The engine was probably fixed after a road accident quite long ago. Later it worked for a time until it got abandoned and dried completely. It was probably the gear changer that got blocked.

The alternator is complete and shows no mechanical damage. Wire is damaged and brushes must be replaced.

The engine cover is complete, in a good condition.It needs repair at the point where the kickstarter's spring is attached.

The right engine crankcase is good.

The left engine crankcase has been repaired once. The bearings could be inserted on glue, so that the insertion ring doesn't have to work so hard.

But this crack is disturbing: it is at the point where the starter release pin should be screwed in. Here, the shock loads are expected.

Gear box is in a very good condition

The clutch is complete and clutch plates in good condition.

The lever and gear changer bushing are worn. Replacing the bushing should be enough to fix it

The set of screws has been completed and the screw holes have been rethreaded

The interrupter has been fixed, cleaned and completed.

The engine is ready for trial assembly."Here you can see an additional spring plate, pressing down on the problematic contact point.

The engine is ready to be assembled for a test

Fuel tank is in a bad condition. Welded and soldered many times.

The gear shift joint and all threads need to be repaired. Sandblasting and later a thorough inspection are required.

Saddle springs are damaged, welded to a frame. To be repaired or replaced

Most parts are ready for sandblasting

The wheel hubs are from the SB model. In the KS catalog we can see the KS model has got hub caps made of thin sheet metal, and only insertions of the thick sheet metal. The KS rear hub is riveted to the drum, undetachable. Of course, the hubs can be reused. Perhaps such hubs were used in some production years of KS model.

Motorcycle parts are washed and sandblasted.

Each part has been examined to find all cracks and deformations. Some parts have been straightened and some cracks have been welded.

Broken, loose holes are fixed. Loose parts are welded in. Worn and scratched areas were hardfaced by welding.

The broken part of the frame head was recreated.

All parts have been covered with anti-corrosion primer.

The front hub has been assembled. The speedometer drive is missing.

The frame head bearings have been inserted. The frame is being assembled now.

The frame has been assembled, the axles are repaired. New bushings are made to replace the missing ones.

The bearings and swing arms have been added. The top cover of the steering damper and the shock absorber arm cup are missing (will they be made or purchased?).

The trapeze has been was assembled together with the spacers, and the front hub has been fitted in.

The trapeze spring is not like the one decribed in parts catalog. The spring in catalog is stiffer, with plates. This may cause the suspension to be softer then planned.

The center stand has been fitted. Cracks are welded. Missing lower sections have been recreated.

The rear fender is damaged. It needs a major body repair.

The rear saddle disassembled. Some components need to be repaired. The cover to be exchanged.

Front fender has been repaired and is in place.

Rear fender has been repaired together with its bail, luggage rack and tool box.

Now the main elements of the body are ready.

The front lamp and license plate are mounted.

The license plate and light mounts have been added. Rear fender components are installed.

The rear hub has been assembled. New bearings are installed, and new brake pads are riveted.

The hub has been adjusted and the chain guard has been repaired. Should we have a pump on the chain guard?