1966 Kawasaki A1 Samurai restoration project

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Topper wrote: Funny, I just found this on ebay today and thought what a cool old Kaw, I've never seen one like that and then I stumble on your post.

That one is an A7. Mine is an A1. Very similar models that shared a lot of parts though

git er done!!!!

SO I haven't quite started the tear-down yet. I am almost done putting the 750 back together then need to straighten up the garage first, but I figure I would ask a couple questions I know I have now, to get my answers by the time I need them.

1. When painting the frame, is there a particular type of paint and/or primer (in rattle-can form) that is preferable?

2. How do you keep the VIN from disappearing when painting a frame? Is there special prepping to be done here, or something after painting?

3. Do you clear coat a painted frame?

4. I know I can't shift into 1st gear. When I finally get into the guts of the transmission, what am I looking for as possible causes (I would have no clue without suggestions)?

Thanks for any and all answers

~Clutch

This project has finally commenced!!!! I'm starting this project with a complete tear-down...which I'm beginning with an overnight oil drain (since it's cold). I have never worked with a 2-stroke before, which this bike is just fyi, and thought the oil looked a little strange. It came out looking clean, but had a strange greenish color to it. Is this normal for two stroke oil??

Anyway, I will be finishing up the 750 tomorrow, moving that into the other garage, clening up the project garage, and starting the actual tear-down. I will take lots of pics (which I know you all love), and will have some up tomorrow

i love two strokes :woohoo: .

just so you know :whistle: .

being as how two strokes gear lube is only in the transmission you will get coloring more from the heating and cooling of the clutch ,and the wearing of the clutch fibers than anything else.
i run bel-ray gear saver in my banshee and it starts out a red color (like atf)and as the clutch wears it starts getting grey streaks in it.it is it's own best indicator of when to change it.
keep us posted,
leon

The aftermath of the 750 project...and the mini project for the day...messy garage! LOL!

531blackbanshee wrote: i love two strokes :woohoo: .

just so you know :whistle: .

being as how two strokes gear lube is only in the transmission you will get coloring more from the heating and cooling of the clutch ,and the wearing of the clutch fibers than anything else.
i run bel-ray gear saver in my banshee and it starts out a red color (like atf)and as the clutch wears it starts getting grey streaks in it.it is it's own best indicator of when to change it.
keep us posted,
leon

Well, after reading that my A1 should get 80mpg...I think I love them too! I plan to make this a daily rider to save oodles of money on gas. Now, this may be a silly question, but will I need to add oil to the gas as well...or is that just something you need to do on simple 2 stroke engines (like weed wackers)? I'm sure it tells me in the manual somewhere, but I haven't perused it enough to find that info yet.

it should have oil injection unless someone remove it. Not sure if this would be a good daily driver. No power until well up into the RPM's but once there its got a little pop! Just my .02 cents. Definitely a cool bike though!!

harm wrote: it should have oil injection unless someone remove it. Not sure if this would be a good daily driver. No power until well up into the RPM's but once there its got a little pop! Just my .02 cents. Definitely a cool bike though!!

I'm pretty sure the oil pump is still in there. I will find out for sure when I get into the motor. Reading up on these bikes, they claimed to have given the 500 and 600cc four strokes of the era a run for their money....must have been a shock to those guys! LOL!

EDIT: WARNING!!!! Very long post...but it's mostly pictures! :woohoo:



So.....I cleaned up my mess from the 750 project, and now there is plenty of room to move around and get into this bike.




I put it in its spot for tear-down, and did a walk-around






On a random side note, I tested the battery...it's been off the charger for about a week now, and still holding above 12 volts...let's see how it looks when it's time to put it back in the bike. LOL!



Moving on....


So a while back when I painted the 750 orange, I spilled a bit of paint on the A1...and the floor...will be cleaning that up




And here are many more of the before pics I took today...I have already removed the gas tank, oil tank, side cover and seat a while back...so...a few less things to mess with in the tear-down phase




Someone cut the front fender down...maybe they were going to cafe it or something....what a shame...it's in decent shape otherwise.








I remember hearing someone saw that these rubber boots are hard to find. Mine don't look in terrible shape, but there are some slight cracks that hopefully don't go completely through.




These screw heads look very shiny...I'm assuming they're not 45 years old and that someone has been in at least a few of the covers...













Most of the cables need to be replaced (clutch and front brake). Amazingly enough...the rear brake cable works ok




Sweet! A little oil checker dipstick cap! (I'm entertained by the simplest things lol)



Electrical...




Not sure if these scratches will come out easily???




ANd last, but not least, my absolute personal favorite...homemade gaskets using silicone....can't wait to see the engine gaskets! LOL!

real cool...10

Somwhere in this world a SL 350 Honda is missing its tires