1966 Kawasaki A1 Samurai restoration project

So I went out to get a pack of smokes a couple hours ago, and when I got home, I went straight into the garage. I thought I was done for the day after cleaning up the mess in there, but I started getting things ready to remove the engine. Carbs are out, chain is off, exhaust is off, all cables and hoses and wires disconnected. All that is left to pull it out other than removing the mounting bolts, is getting the stubborn tach drive cable out of there. It is held on with a knurled nut that just wont budge. I have 3-in-one oil soaking on it overnight to hopefully loosen it. Sorry guys...no picks, but I promise I will take some of where I'm at before I start again tomorrow...and then hopefully some with the engine out too! :woohoo:


EDIT: I also pulled the plugs to have a look at them...they look ok, but honestly I don't think they're the right ones, and two different brands. Basically looks like the PO threw something in there so I could start it before I bought it...

Oh...forgot to mention that it only had an exhaust gasket in one side, the other side had a noticeable amount of oil in the header. I know the exhaust gasket wouldn't prevent that, but it was an interesting observation.

I went back out to the garage with my camera to take a few pics of a wheel I have that another member is interested in, so here are some shots of where I'm at right now...


Left and right side with covers and carbs removed.




Carbs hanging out until I removed the cables from them




Parts laid out, organized, and mounting hardware is separated into labeled ziplock sandwich baggies so I can easily locate them when putting it back together.




This is the stubborn little booger that just won't budge...still...

So I finally got that stubborn knurled nut off to remove the tach cable. I ended up having to use a small pair of vise grip pliers to get a good grip...and even that took several tries!



Then I removed the motor mount bolts, and proceeded to remove the engine, but this air cleaner mount was in the way, and I stripped the screw. I did get it off with a screw-out tool and my drill.



Finally! It's out!




A few pics of the swingarm and frame grime. Not too bad considering how old this bike is I think...





So step one of the tear-down is complete. The engine has been removed! The rest of the tear-down should be much easier. I will start with removing electrical, then the swingarm, then the forks. Then the real project begins...cleaning it up and putting it all back together! LOL! :woohoo:

that should be a fun little project!

wireman wrote: that should be a fun little project!

So far it is! I have a strong feeling that the most stressful part of this project is going to be finding the parts that I need to restore it back to original! So far that is still my plan, but if there is a lot I can't find, I may end up making this an A1R replica....though a stock restoration is my hope!

i know a good plating shop if you need one

wireman wrote: i know a good plating shop if you need one

I may end up needing them for the rear fender if my cleaning and polishing skills aren't as good as I'm hoping them to be. LOL

you might be suprised how little it actually costs to replate all the chrome parts on a bike,banged up chrome detracts from nice shiny black painted parts! :laugh:

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

leon

Me too! I've have mine for 26 years and it's never given me a bit of trouble. Here's a pic of one that's identical to mine:




:whistle:

650ed wrote:

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

leon

Me too! I've have mine for 26 years and it's never given me a bit of trouble. Here's a pic of one that's identical to mine:

Attachment scamp.jpg not found

i still have nightmares about pushing a lawnboy as a kid! :sick: :woohoo:
:whistle:

wireman wrote:

650ed wrote:

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

leon

Me too! I've have mine for 26 years and it's never given me a bit of trouble. Here's a pic of one that's identical to mine:

Attachment scamp.jpg not found

i still have nightmares about pushing a lawnboy as a kid! :sick: :woohoo:
:whistle:

Look! It's even Kawasaki Green!!! :silly: