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The pictures here show the Zündapp as I go it delivered during 2016 from Dutch Lion in Belgium (plus a box of parts). When you buy a bike like this it is bit of a gamble as to the condition; however before I bought it did get photos of the engine, carb, etc to make sure it was complete and what it was advertised as and researched the company selling it. Frustratingly, I forgot got to ask about the Kardan drive gear housing, only to find the crown wheel was missing and one exhaust is not correct, which I think most dealers would have point out!

I had read some bad press about the people that run Dutch Lion Motorbikes before I bought it and their alleged involvement in a company called Investment Bikes, which apparently had a reputation for selling bikes that were in worse condition and non-original parts but described as original or working etc. I was a bit annoyed that they didn't mention the missing crown wheel or exhaust, but you will see that their emails are very short as to say as little as possible.

That said, the bike was mostly as described, it was delivered when they said it was and I had no problems with the transaction. I paid by bank transfer and the bike turned up..I did feel a bit nervous at the time, but there was no problem. Would I buy again from them? yes, but ask for extra photos if needs be and assume you will have to strip the bike; you will then be fine.

Inspection And Parts List

The first thing I had to do was spend months studying photos and parts diagrams to figure out what was missing and make a list. This is actually a very complex and time consuming task. You literally have to click on each item for sale and say..have I got one of those, then find out the difference between WW2, post war and repro!

Some of the parts are super rare and super expensive, in particular the unique Ölstossdämpfer or Oil Shock Damper that fits to the top of the springs and holds the handlebars.. This is a very expensive precision engineered part, so a worn or rusted one is no use - if you can find one anyway. I have seen just one for sale in two years that was in Poland and rusty - world wide! The impossible parts are things like the BW38 Zundapp Frame, the speedometer, good pressed steel foot boards, the BW38 fender light etc. By pure coincidence, I happened to be doing my daily part scan and found a rough BW38 frame for sale in the UK!. I won't say how much it cost, but you will be lucky to get any change from £1000-2000 or £3000 with a boat (as at 2017). You do see the frames for sale in Germany but they are not the easiest thing to post.

The list seem to grow and grow, so I decided to do some serious shopping on and ebay small ads Germany ( These are often a good list of parts, I also decided to teach myself German at the same time. Unfortunately Brexit had caused the exchange rate to collapse just as I need to buy loads of expensive parts! This has taken a year so far!!

Stripping The Motorcycle

When undertaking a task of this scale, it is vital to document, photograph and neatly store everything. One of the most important things is to keep parts separate and note their orientation!. So for example if you take out a piston connection rod, mark the cylinder it came off with a dot of tippex, the crank, the engine side, which way up the rod was and what bearings and rollers were with it - then keep these separate from the other side (parts wear together). With bearings and gears mark which was was facing what.


The frame is just like any other bike you may restore. I like to strip back to metal and weld any spots, then grind. On German WW2 motorcycles I always prime with a red oxide and it helps if you pre-heat / warm the frame. This helps the paint bond better when applying a first thin coat.

Front Fork and Oil Damper


Wheels and Bearings


Rear Wheel Kardan Drive


Engine - Pistons rods and needle bearings (Pleuel,Nadeln und Käfigen)

As the heart of the engine and the subject of myth and legend, this section warrants a separate page. As such, I have analysed the rods and needle bearings and created the world's most in depth analysis of the Zundapp K500, KS600, KS750 and K800 piston rods and needle bearings!

Here i will explain how the split cage needle rollers work, why they fail and how to install them correctly. I also show how to adjust them and if you should change them to shells / journals. - Thank me later!

Oil Pump - Ölpumpe Oil pump restoration, testing, flow and function.

The oil pumping and cleaning system is of course vital to the function of the engine. Watch the video where I explain how the oil flows and how to fit and repair the oil pump. I will add more info soon.

Gearbox / Transmission


Steib BW38 Sidecar


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Julian   15/06/2018 at 12:57:53
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Hernan   13/06/2018 at 00:35:42
Hello Sir. I just wrote you in Youtube. My name is Hernan Morales from Uruguay. I am restoring a 1936 K500 Wehrmatch style. Your help will be greatly appreciated. I may be contacting you from time to time as well as watching your videos. Where are you from? Regards
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 - Julian   14/06/2018 at 22:06:55
Hello. No problem i will send you and email.
 - Julian   14/06/2018 at 22:07:53
Hello. No problem i will send you and email.

Hernan   13/06/2018 at 00:15:50
Hello Sir. I just wrote you in Youtube. My name is Hernan Morales from Uruguay. I am restoring a 1936 K500 Wehrmatch style. Your help will be greatly appreciated. I may be contacting you from time to time as well as watching your videos. Where are you from? Regards
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Rob   20/11/2017 at 15:08:39
Here is a gearbox:
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george   13/11/2017 at 17:41:33
Hello again. Thank you for your reply. I checked on the web you sent me but there is nothing.
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 - Julian   13/11/2017 at 18:22:32
Here is one - but a bit expensive. They are very common item - about 450-500 euro is about right. I will send you an email so you have my direct contact.

george   13/11/2017 at 17:11:25
i am restoring one in MALTA. i am in need of a complete gearbox. can you help me with it? i can t find one.
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 - Julian   13/11/2017 at 17:28:52
Hello. I will ask about for your as I have many contacts. I was working on this page when you messaged. Have you tried

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