1972 Kawasaki H1B Restoration

Discussion in '2 smokers' started by przjohn, Dec 18, 2013.

  1. jimroid

    jimroid Been here awhile

    Joined:
    May 14, 2013
    Oddometer:
    203
    Location:
    Wichita Kansas-USA
    You are kicking some butt! Great winter project you have going.:freaky
    #21
  2. Toto

    Toto Been here awhile

    Joined:
    Jan 31, 2008
    Oddometer:
    476
    Location:
    Mississauga, Ontario, Canada
    :lurk Be careful....be very careful ! :evil




    P.S. Will she be done by spring?
    #22
  3. jimroid

    jimroid Been here awhile

    Joined:
    May 14, 2013
    Oddometer:
    203
    Location:
    Wichita Kansas-USA
    And now your quickest normally aspirated H2 in the world: Joe Bird/Bill Baxter.8.24@155.13.[​IMG]
    #23
  4. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    That is my goal, to be ready for the 2 Stroke Meet in Deals Gap NC beginning of May. Yesterday I finally found an NOS sealed beam for the bike as well as an NOS headlight ring. I am pretty sure that is about it for things I need that are NOS. I have yet to go deep into the motor but with the cylinders off the crank looks good and no corrosion. I will tear it apart next weekend.

    A couple of Winters ago I ended up getting both of these bikes done over one Winter,

    This 77 KH400

    [​IMG][/IMG][​IMG]

    And this 84 RZ350

    [​IMG][/IMG][​IMG]

    If everything goes smooth the begining of may should be possible.
    #24
  5. Frank06

    Frank06 Been here awhile

    Joined:
    Sep 24, 2009
    Oddometer:
    235
    Location:
    Maine
    You are going to change crank seals, etc aren't you? Might as well send the tranny to R&D as long as it's apart...

    Sent from my Nexus 7 using Tapatalk 2
    #25
  6. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    Yes the crank is going to be sent out. I will look at the tranny, but that should be within my capabilities.
    #26
  7. FJ_Kevin

    FJ_Kevin Been here awhile

    Joined:
    Dec 28, 2010
    Oddometer:
    459
    Location:
    Maryland ==> originally from Long Island

    I have been enjoying your posts. Great workmanship... really!

    I have a few general questions on these multi-cylinder 2-stroke cranks.

    - What is the deal with the main seals between the flywheels. I am imagining that you have to press the crank apart to change them? Are they keyed some how to keep the crank pins in the correct relationship to each other?

    - About a year ago I looked at a Yamaha yds3 (twin cylinder). I seem to recall the guy telling me the center crank seal was replaceable without splitting the crank... don't recall the details of this. Maybe you know?

    - If you don't mind me asking, what is the range in cost one might expect to rebuild a crank for your bike? And are you doing just the seals or the whole thing (seals, rods, bearings). I can rebuild a single cylinder 2-stoke crank but am leery about trying a twin or triple :eek1. How did you find your crank rebuilder?

    Thanks and keep up the great work!
    Kevin
    #27
  8. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    The crank gets minimum new seals and bearings. From there it is inspected to see if it needs rods. Last one I had rebuilt was an H2 750 crank that also needed new rods and that ran me $1,000.00 for everything. The rod kit alone is about $350 I think. I will probably send this one out to HVC Cycle who did my last one, I was happy with their work.
    #28
  9. joexr

    joexr Banned

    Joined:
    Jan 4, 2011
    Oddometer:
    5,022
    The center seals are on one side of the bearings. The cranks are pressed together , no keys. Harley cranks aren't keyed either.
    #29
  10. anonny

    anonny What could go wrong?

    Joined:
    Mar 20, 2007
    Oddometer:
    5,952
    Location:
    Beautiful Revelstoke BC
    Yes the trannys are simple, there a lot of good reading on how to shim it properly, the biggest issue is getting the kickstart spring on properly and even that's not rocket surgery

    Have you given any thought to what kind of crank seal you are going to use? Porsche Dave in California has a good reputation for triple crank rebuilding.
    #30
  11. petermac

    petermac Adventurer

    Joined:
    Jan 10, 2006
    Oddometer:
    52
    Location:
    Barrack Point , Australia
    Nice to see this bike saved.

    I bought this exact model new in Australia,rode it on the road and raced it.

    Heaps of fun,fondly remembered,scary handling was excting
    #31
  12. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    Porsche Dave has an excellent reputation and may try him on this one if he has the time available. I have used both Labyrinthe and standard seals with good results. The Kstart issue has never been a problem, though now I just jinxed this one. :huh
    #32
  13. Reverend12

    Reverend12 Well there it is..

    Joined:
    Nov 21, 2008
    Oddometer:
    1,516
    Location:
    Classified
    :clap Going to be a really nice restoration!
    #33
  14. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    Finally got to the rolling chassis this weekend. One of the toughest things to assemble for me seems to be getting the front end attached to the frame without having everything head to the floor. It sounds simple enough, but by yourself attaching the forks and frame to the front wheel always seems to be a balancing act for me. This time I attached the wheel to the lift and kind of wobble walked the frame and forks to it, seemed to work good.


    [​IMG][/URL][/IMG][​IMG]
    #34
  15. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    Getting the rolling chassis together was a big milestone but most of the work this weekend centered around the engine. The crank is now ready to go out for a complete rebuild of seals, bearings, and rods. This is an expensive job and is critical in a 2T restore as the seals must be replaced to have a "New" motor, and, since this is a multi cylinder motor you need to disassemble the crank to do that. I am going to contact Porsche Dave from the Triples site to see if he will rebuild it. The real time consuming part of this weekend was cleaning the cases. It starts with a trip to the car wash, then scrubbing with parts cleaner, and lastly a very fine glass bead. The glass bead needs to be done a few times as there is still dirt that needs to be Dremel wire brushed off from these old cases. I have read about guys who don't glass bead because of either failure potential or because the cases dirty quickly. I clean the bejesus out of them and blow out every orifice and screw hole. There is absolutely no glass bead left in there. I also use an extremely fine bead that doesn't make the substrate suseptible to holding dirt afterwards, almost as fine as soda blasting. It has worked well for me on past restorations. Here is a before and after of the cases and the crank ready to be boxed and shipped. Notice no corrosion at all on the crank, a real good sign.



    [​IMG][/URL][/IMG][​IMG]


    [​IMG][/URL][/IMG][​IMG]


    [​IMG][/URL][/IMG][​IMG]
    #35
  16. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    So, when you do a restoration and spend most of the weekend cleaning cases it is nice to take 5 minutes and bolt on some eye candy. That way, end of day, you can open a beer and admire more of your work. Is it no surprise that is my favorite part of the day? Here is the new hydraulic stabilizer mounted up. I am not putting the static stabilizer back on the triple clamps. Here is a pic of the hydraulic unit mounted and the triple clamps with a standard Kawasaki bolt and washer instead of the static stabilizer. Notice the new fork caps and all mounting bolts are new reproduction too.


    [​IMG][/URL][/IMG][​IMG]



    [​IMG][/URL][/IMG][​IMG]
    #36
  17. vtwin

    vtwin Air cooled runnin' mon

    Joined:
    Jan 11, 2005
    Oddometer:
    7,999
    Location:
    NorCal
    I know a guy that specializes in these cranks. Let me know if you want the link.
    #37
  18. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    This was another weekend of prep work. Saturday was spent cleaning heads and cylinders. The cylinders are in the truck and will be dropped off at Eastwood Machine in Somers, CT. With the crank now safely delivered to Dave Singleton, AKA Porchedave in California the engine build should come together in a few weeks.
    [​IMG][/URL][/IMG][​IMG]
    #38
  19. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    Another prep job that got done was the front caliper rebuild. I have been using Zip Strip to remove paint from parts first and then using a fine bead to remove the last bits. Seems to be easier as the fine glass bead doesn't remove paint well. Here is a before first, then the housings painted with the kit including new piston, and finally the caliper on the bike.


    [​IMG][/URL][/IMG][​IMG]


    [​IMG][/URL][/IMG][​IMG]


    [​IMG][/URL][/IMG][​IMG]
    #39
  20. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    203
    Location:
    Ellington, CT
    The next job that was to be tackled was the seat.


    [​IMG][/URL][/IMG][​IMG]

    But then there was this surprise. The seat pan is N/G. I have ordered a new reproduction one from Z1 Enterprises.


    [​IMG][/URL][/IMG][​IMG]


    So, it was move on to the front pegs.


    [​IMG][/URL][/IMG][​IMG]


    The springs, washers, and clips were all run through the Zinc plate process.

    [​IMG][/URL][/IMG][​IMG]


    Then attached to the freshly painted stalks with new reproduction grips.


    [​IMG][/URL][/IMG][​IMG]
    #40