1966 Kawasaki A1 Samurai restoration project

I used one of those wire cup brushes to strip my old exhaust, learned the hard way that you need some tough clothes on. You dont even feel the wires going in cause they're so hot. I pulled about 10, one inch long wires out of my forearms at the end of the day.

Can't wait to see this thing done, should be killer!

T_Dub wrote: I used one of those wire cup brushes to strip my old exhaust, learned the hard way that you need some tough clothes on. You dont even feel the wires going in cause they're so hot. I pulled about 10, one inch long wires out of my forearms at the end of the day.

Can't wait to see this thing done, should be killer!

Had you told me that the other day, I might have thought to wear a hat as well...I pulled one out of my scalp the other night. It scared me a little to wonder if it could have gone through my skull. Next time I will be wearing a ball cap at the very least with all my other protective stuff!

A little more progress on the project. I started spraying the Rustoleum Satin Enamel on the frame and stands. I am very excited about this project now, because I now am certain it is going to look like a brand new bike!





I also taped off the shocks for painting the sleeves. I will do this while the frame and swingarm are drying. That way, when I'm done spraying these, it should be time to start putting the pieces back together. The chrome on these is immaculate, so I am going to run them as long as they provide a little cushion!





The hard part, is that since I need to spray the shocks so early, I need to decide on my paint scheme. I've mocked up some really low quality ideas, and want to hear you guys thoughts.





I'm not very original as the two on the left are more or less stock, and the top right is based on the stock. I mocked these up with the rear fender painted, but I may be able to clean up the chrome, or fork out the $$ to have it replated. I think my favorite is the bottom right though. What do you guys think? Feel free to modify them and show me what you get. I'm actually thinking a non-stock paint scheme will look better with the bike rebuilt.

I'm liking the bottom right too.
Also sent you a PM.

Chaotic Reason wrote: I'm liking the bottom right too.
Also sent you a PM.

Thanks for the input. Got your PM and replied.

clutch wrote: ...I need to get at the transmission and figure out why I can't shift into first gear....

I may have just found the answer without even tearing down the engine! I found an article on the A7 from 1968. Reading through I found this:

"In Continental fashion the gear changes on the left -down for down, and up for up, with neutral right at the bottom."

So...maybe there is no transmission issues!!!! I'll be keeping my fingers crossed for that to be true!!! :woohoo:

I started clearing the top half of the frame today. My painting skills are definitely improving.





I was a little nervous about clogging up the VIN. I actually did with the paint the other day, so I had to sand it down and reshoot that. It turned out well enough to read it, though it may be slightly difficult in the pic.





I will probably finish stripping the battery box today, and at least start on the swingarm. If I have enough time, I'll sand down the shock sleeves as well, so I can start priming those once the frame and stands are out of the way. Then, I will be working on the forks and wheels, and I can start putting the bike back together. I will be waiting on parts though...new bearings (steering and wheels), new brake shoes. I already have some new tubes for the tires, but I'm not sure what to look for on the tires themselves to see if they need to go (I'm used to tubeless).

I'm looking for suggestions on cleaning up the triple clamps. I'm thinking a little light sanding will be ok, but I'm not sure of the stock finish. It looks to just be cast metal, with no paint, but I'm not sure...





And I just realized the bottom clamp is painted...something else I need to strip and paint...great....

I saw one low mileage one which looked like it had just plain aluminum clamps. I'd suggest some soda blasting. Clean them up and leave them plain.

T_Dub wrote: I saw one low mileage one which looked like it had just plain aluminum clamps. I'd suggest some soda blasting. Clean them up and leave them plain.

Just the top is plain aluminum on mine, the bottom is painted black. I did pull the bottom clamp off the forks today. I may end up just sanding that down to the aluminum to match the top clamp. I cleaned up the top clamp earlier too with some sand paper and then a little wire wheel on my dremmel. It came out ok, but I want to figure out some way to even out the shine a little more. I took a pic of it that didn't turn out well, but left my camera in the garage.

I splurged a little today. I bought some new steering bearings, cotter pins, tire irons $ rim savers (gonna teach myself to change a tire), and a m6 x 1.0 tap with a t handle (should come in handy someday). These things should keep me busy on the project for a little while...at least until next payday. LOL

use a magnet to check that lower.
kinda looks like steel to me, :whistle: .

sooooooo,




i vote paint the lower black and polish the upper :evil:


leon