1966 Kawasaki A1 Samurai restoration project

531blackbanshee wrote:

Kidkawie wrote: I can only get 55mph on my KE, trying to get another 10mph out of it. Those rotary engines have a ton of potential.

this from the guy that said:

You have a 45 y/o bike, the last thing you should be worrying about is performance. :pinch: :whistle: :silly: :woohoo:

leon

It seems he's dead set on modifying the bike, so instead of completely ruining it I figured I'd at least point him in the right direction.

Personally, I would leave it as-is.

Kidkawie wrote: [ It seems he's dead set on modifying the bike, so instead of completely ruining it I figured I'd at least point him in the right direction.

Personally, I would leave it as-is.

your idea of the "right" direction may only seem "right" to you.
that is the cool thing about this forum we don't have to all do what someone else thinks is "right". :kiss:

whether we restore or modify,
all that matters is that the person who owns the bike is happy with it .

after watching the videos of a bike like clutches with the chambers on it on the highwayman site there is no way "I" would have anything but. :evil:

keep us posted clutch i can't wait to see how it turns out.

leon

531blackbanshee wrote: your idea of the "right" direction may only seem "right" to you.

ok, whatever Bro. I made up the Clymers reference and Klemms really makes meat grinders. :whistle:

I RULE!







Looks like the 3-in-1 oil did the trick again! I love that stuff!

Since there's much discussion about modifications, here are my plans for the bike:

1. Safe and functional
2. Clean
3. My own paintjob
4. Possibly aftermarket exhaust to replace the dinged up mufflers
5. Possibly replace rectifier with a reg/rect
6. Polish the engine, rather than paint (the plan so far)
7. Possibly aftermarket mirrors
8. Possibly aftermarket turn signals
9. everything else stock, with the exception of a complete rewire

No performance modifications will be made. These bikes had a claimed top speed of 103mph stock. They also had a claimed gas mileage of 80mpg.

sounds like a solid plan.

it should be pretty danged nice by the time you get her all done.

congrats on the case split :lol: .

leon

531blackbanshee wrote: sounds like a solid plan.

it should be pretty danged nice by the time you get her all done.

congrats on the case split :lol: .

leon

Thanks. I think I just began the most time-consuming section....well almost. Polishing that engine is going to take some time and elbow-grease. I will definitely need advice making sure everything is lined up correctly when putting it all back together, as the manual isn't very specific on the transmission reinstall. The way my manual says to reassemble it (upside-down), I won't be able to go with my plan of rebuilding it in the bike. Once the cases are back together, I will put it in and finish reinstalling the pistons, clutch, etc on the bike. When I get home from work later, I will work on getting all the shafts out of the cases so I can clean them up a little easier. There's no going back now! LOL! :woohoo:

shoot man you won't have no trouble!

we build banshee lower ends the same way,upside down on a wooden box on the bench.

no real reason not to build the top end at the same time either is there?

these pictures you have posted here will be a big help to re-assure you that you are installing everything correctly.

i always take pics of late model power valves when i am taking them apart to sleeve or bore and hone them.those pics are the only way i have been able to get some of them back together.i just do the machine work so it is not feasible for me to get manuals for everything i have worked on.

digital pics are a big help for re-assembly.

leon

531blackbanshee wrote: no real reason not to build the top end at the same time either is there?

I just figure it will be lighter, and less bulky, so I will have a smaller risk of scratching up the frame paint putting it back in before...though I may do the pistons first...in case I drop another pin from a needle bearing and have to split the case again. LOL...that would stink!

clutch wrote:

531blackbanshee wrote: no real reason not to build the top end at the same time either is there?

I just figure it will be lighter, and less bulky, so I will have a smaller risk of scratching up the frame paint putting it back in before...though I may do the pistons first...in case I drop another pin from a needle bearing and have to split the case again. LOL...that would stink!

ah good call there man .

leon

here is how the sanctuary guys keep from scratching up nicely painted/coated frames.





some vinyl or rubber tubing split lengthwise and slid over the frame,to protect it.


leon

531blackbanshee wrote: here is how the sanctuary guys keep from scratching up nicely painted/coated frames.

some vinyl or rubber tubing split lengthwise and slid over the frame,to protect it.


leon

Not a bad idea. I may have something laying around similar to that.

I got the crank shaft, transmission, kickstarter, and output shafts out of the cases. All that's left is the shift drum in the top half and the shift lever in the bottom. I think they will be out of the way enough to clean the cases up, so they may stay in.

I'm a little nervous about lining up the shift forks and transmission properly. How can you check that before putting the cases back together? Can you just click through the gears to make sure it's correct? My manual shows some great pics of the transmission gears, and how those line up, but without the shift forks...