Kawasaki ZL 600 – Louis special conversion

AI generated: Purple and black custom motorcycle with chrome accents and white-walled tires.

AI generated: Black Kawasaki Z400 motorcycle with chrome accents and a classic design, positioned on a white background.

Kawasaki ZL 600

- before the renovation

Trainee Bike 2025

Turning a forgotten machine into a real statement

– that was the mission of eight motivated trainees. The dusty, rusty and long-disused Kawasaki ZL 600 was transformed into the Trainee Bike 2025. A motorbike that looked more like it belonged in a scrapyard than on the road. But that was precisely the challenge for our young trainees. From the outset, it was clear that the old chopper was to be turned into a modern bobber. Our trainee team had five days and a budget of €2,025 to create something completely new and unique from the old bike.

First of all, everything has to come off.

Even before the project could officially start, ideas were already flowing, and the trainees worked together to develop the initial concept for what is now known as the Trainee Bike. When the next day dawned, the team got straight down to dismantling the bike. Parts were unscrewed, sorted and evaluated: what could stay, what needed to be replaced? Because one thing was certain: the bike couldn't stay as it was. Except for the frame, the bike was dismantled so that the components could be specifically reworked. Defective parts were replaced with new or homemade components, because the goal was to reuse as many of the old components as possible.

A great deal of hard work

The project involved dust, sparks and precision: lots of sanding, thorough cleaning and intensive derusting. These are all crucial steps to ensure a durable paint finish. Superfluous elements such as the passenger seat and the second silencer were removed to modernise the design and reduce weight. The trainees decided to cut off the entire rear end and replace it with their own design. This process, along with the installation of new springs, turned the bike into a low-slung bobber – an important step in the major transformation of the motorcycle.

AI generated: Three people working on a disassembled motorcycle engine on a workbench in a well-lit workshop.

AI generated: A group of people posing with a disassembled motorcycle in a workshop. The main subject is the motorcycle.

Powder coating

PulveaWhile most of the team was busy upgrading the bike, three of our trainees visited the powder coating facility. There, our trainees coated the tank, rims, brake calipers and other small parts themselves. Powder coating provides metal parts with particularly effective protection against mechanical abrasion and environmental influences. Unlike liquid paint, the powder forms an exceptionally even, hard surface when baked, making it less susceptible to scratches. This not only gave the tank, rims, brake calipers and other parts a high-quality appearance, but also a durable and strong protective coating.

AI generated: Open cardboard boxes containing various motorcycle parts, including a seat, engine components, lights, and wiring.

AI generated: Motorcycle parts including a fuel tank and wheels laid out on a red and black striped cloth near a window.

Midnight Purple

However, the bike still needed to be painted. But our team of trainees was not lacking in determination. The frame and attachments were degreased, primed and painted. The frame was given a deep black finish and the attachments shone in an intense ‘midnight purple’. And thanks to the primer under the paint, which also ensures the necessary adhesion of the paint layers, the parts achieved a great result.

The assembly

The freshly painted parts were reassembled, cables laid, brackets adjusted and screw connections checked. But despite all the effort, something was still missing. At the same time, the team came up with a homemade design for the motorcycle seat. Three of the trainees visited the upholsterer to cut the upholstery, sew the cover themselves and fit it. The team also thought of a suitable name for the bike. It couldn't remain nameless... The team christened the bike ‘Bobbina’ and embroidered this name onto the motorcycle seat.

AI generated: Motorcycle frame and engine on a lift in a workshop, with the front fork assembly removed and secured with straps.

AI generated: Two people working on a motorcycle frame in a workshop.

And so the final day dawned, marking the start of the final phase. Cosmetic corrections, fine-tuning and technical refinements were completed. The brake fluid was changed and the electrical connections tested. The rims also received some attention, with decorative strips added to enhance their appearance.

Das Design

Our trainees opted for a striking shade of purple, for example on the tank and brake calipers, combined with white rims for a modern contrast. Purple decorative stripes and purple stitching on the motorcycle seat added further exciting accents. The result was a blend of modern look and classic retro bobber style – a unique look for a unique motorcycle.