Kawasaki A7 Avenger 350

Discussion in '2 smokers' started by johnnyc14, Oct 29, 2011.

  1. johnnyc14

    johnnyc14 Been here awhile

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    I got the bottom end of the engine re-assembled and installed back into the frame. There is a lot more to this engine than other 2-stroke twins I've had.

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    #21
  2. Sniper X

    Sniper X De Oppresso Liber

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    This is a great build thread. The thing is going to look new. Good job!
    #22
  3. johnnyc14

    johnnyc14 Been here awhile

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    Thanks Sniper X. More progress today. I learned that one of the differences between the 250 A1 engine and the 350 A7 engine is there is an extra set of oil passages drilled into the 350 case that feed the outer main and rod bearings. These passages are fed from the main oil injection fittings on the rotary valve covers and there is a special bolt in one position on the cover that has an oil bypass groove machined into it. My engine was missing these bolts and there were just ordinary screws in place of them. There must have been enough oil getting past the threads to keep the bearings happy because they were in good shape. I found some of the special bolts on ebay and they finally arrived yesterday. This is the bolt.

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    It goes in the top hole on the rotary valve cover.

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    After I got that straightened out I got the top end of the engine assembled with new rings, wrist pins and bearings.

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    New points and condensor and I also replaced the wires from the conensor to the points as they were in rough shape.

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    It's coming together.

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    #23
  4. twoskies

    twoskies n00b

    Joined:
    Nov 24, 2011
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    really nice build, i just bought a 71 kaw a7, real rough shape, mostly complete but rough, motor locked up, i was thinking of selling it the way it is but after seeing your post i think ill fix it, thanks for the information and ill keep track of your build
    #24
  5. McJamie

    McJamie STROMINATOR

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    I thought all the A7's were electronic ignitions. Clearly I was wrong.
    I am hoping to have mine finished soon as well. It's good to see there are still a few of them out there being brought back to life. It probably wont be as clean of a job as what you are doing, but my plan has been to do everything myself. With the exception of having the cylinders bored ( by my friend, the late Steve Crover ), I have managed to do that. I'll post some pictures soon.
    #25
  6. johnnyc14

    johnnyc14 Been here awhile

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    McJamie, I think all the 67 and maybe 68 A7's were point ignition. I saw some of your post over on the A series forum but there's not too much activity over there. I have 2 A1 parts bikes so f you need any parts let me know and maye I'll have a spare.
    I got some more work done. I took the ignition switch apart and cleaned it and replaced the hardened and cracked wire covering with heat shrink. This switch has 2 extra wires that are not shown in the schematic, a green and a yellow. I spent some time figuring out what they are for. One phase of the generator is connected to the green and it goes to the ignition switch where it is connected to the yellow only when the switch is in the "lights on" position. The yellow then comes back to the rectifier. I am installing a custom built regulator/rectifier from Oregon Motorcycle Products so I'm going to bypass that part of the switch. The modern regulator will have no problem dealing with full generator output even with the lights off.​

    You can see in the schematics below that the green and yellow wires are shown at the ignition switch on the models with CDI but are shown not connected to anything, they are not shown at all on the points ignition model.​

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    I got the carbs cleaned and rebuilt. I bought some Keyster carb kits and of course almost every part in them is wrong as usual. The only parts I used were the needle/seat assemblies. Good thng they were cheap.​

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    I had a clutch cable left over from my Honda CL450 build and I found that it is a perfect fit on the A7 and is a much better quality cable than the original!! Cool.​

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    Well that's enough for tonight, I'll post some pics of the regulator/rectifier install later.​
    #26
  7. McJamie

    McJamie STROMINATOR

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    I'm in the process of redoing ALL of the wiring. When I first got the bike, I cobbled it together enough that I thought it was usable. I decided I can do a little better then that. I've got all winter now ( snow & freezing rain yesterday, been riding up until then). I'm going to switch the garage to "Winter Mode"( new bike at the back, old bike that needs work at the front), on the weekend. So hopefully I can make some real progress soon.
    I actually have a pretty large stockpile of spares myself. I lucked out at the Paris vintage meet a few years back. A guy had a van load of parts he didn't want to take home, including a complete SS exhaust system. That alone was worth his asking price.
    #27
  8. johnnyc14

    johnnyc14 Been here awhile

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    That's great, one thing I haven't figured out yet is what I'm going to do for an exhaust system. All the exhaust on the 3 bike I've got is in bad shape.
    #28
  9. Sniper X

    Sniper X De Oppresso Liber

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  10. johnnyc14

    johnnyc14 Been here awhile

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    Thanks Sniper X, I've tried to email him a couple of times but he does not reply. I have a pattern for copies of A7 chambers originally built by J&R. I have a friend who works at a metal fab shop and I am going to ask him to make the chamber cones and I'll weld them up. They are pretty simple as there are no bends, you use the original head lead pipes.

    When I was checking the electrical stuff I found that the rectifier has 2 open diodes. I used an Oregon Motorcycle Products rectifier on my Honda CL450 so I contacted Tony at OMP and sent him a schematd of the A7. He made some small mods to one of his existing rectifier/regulator combos and sent it out to me. Here's the old parts and what I replaced them with.

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    I used a common ground point for everything.

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    I made up a simple bracket for the unit and installed it in the same location as the stock parts. It looks a lot neater and i know the charging system will work perfectly. Tony make good parts!!

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    I made up new battery cables and used a modern automotive mini fuse instead of the old glass tube style, an added benifit is that the fuse holder is sealed.

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    I used an old inner tube to make up a new mat for the battery and installed 2 side cushions for the battery. The cushions are H1 parts and I just had to drill a couple of holes to install them. I had to make a new battery door/bracket out of a piese of aluminum I had laying around.

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    The lights all work and I've spark from both coils !!! Cool.
    #30
  11. olddog58vette

    olddog58vette Been here awhile

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    Come on man.......WE NEED MORE!! :lurk:lurk:lurk:clap:clap:clap
    #31
  12. McJamie

    McJamie STROMINATOR

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    Still Waiting for MORE please.
    I've been working on mine a bit lately, need a little inspirational prod ( read = pictures ) to keep going.

    Also; Anyone know why I can't seem to locate the A1/A7 series forum. I had it bookmarked on my old computer( before it's untimely demise ). I know things move rather slow over there, mostly I think due to the few # of people that still have these bikes, but there's lots of good information that doesn't seem to be anywhere else.
    #32
  13. McJamie

    McJamie STROMINATOR

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    I just finished putting the carbs back together. They were surprising clean, but should be better regardless. I also found a brand new OEM throttle cable I didn't even know I had. It's actually the optional one for the lower bars which is what I'm using anyway. I don't even remember buying it.
    I'm starting to get excited about finishing this thing.:ricky
    #33
  14. Mulewright

    Mulewright Old Fart/Journeyman

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    I had a A-7 back in school.... mine had "Filtron" pod air filter that hose clamped to the flange on the stock a/f housing & worked well.
    Opened up the rotery valves on the "closing" side .040", "Blueprinted the cyls. with a .015" higher exaust port & port matched everything. and re-jetted the carbs & a set of "Bassini" expansion chambers w/ built in silencers.
    I sold it when the "new" 350 Triples came out..... big disappointment.
    My "Old" 350 would jerk the headlight out of my new Triple..... totaled it after 3 months (truck on I-40 lost a culvert in front of me), used the insurance check to land a new H-2.
    Things were much etter then.....
    #34
  15. johnnyc14

    johnnyc14 Been here awhile

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    I have finally started work on the A7 again. I got the tins painted, got the tank panels re-chromed and got new rubber tank pads made up.

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    #35
  16. McJamie

    McJamie STROMINATOR

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    Once again, the quality of your work is putting mine to shame. It looks really, really, good. I like the more modern style turn signals, they really do seem to suit the bike. Where did you get them?
    Which brings me to a question; I'm still trying to get the wiring sorted on mine, and I can find no evidence of turn signals anywhere. Mine is a 1970, and I wonder if they were an option. Did yours have them, and is the switch on the left handlebar housing like everything else?
    I'm also pleased to see you put some good tires on it. Too often they part gets skipped on an older bike, or they put something more period correct. It should be a brilliant bike to ride when it's done.
    Have you had it running yet?
    #36
  17. volkrt

    volkrt Adventurer

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    just an outstanding resto job and I really like your attention to detail and the improvements you have made to it.....do you mind if I ask if you had new cci lines made up or did you find some nos?
    #37
  18. johnnyc14

    johnnyc14 Been here awhile

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    Thanks for your comments. I think those little "billet look" signals look good too. They came from Jessbikes.
    http://jessbikes.com/product_info.p...id=59&osCsid=28bcade7e5ecca7b5404c588c8c412eb

    Inside the headlamp housing the dark green wire comes from the signal switch on the right handlebar to the left signal lamps. The grey wire is for the right lamps. I have a wiring diagram. If you would like a copy let me know.

    I have not had it running yet, still waiting for a fuel tap.
    #38
  19. McJamie

    McJamie STROMINATOR

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    Thanks, I will look again next time I'm out there.

    PM sent too.
    #39
  20. anonny

    anonny What could go wrong?

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    Looks great, who are you using for chrome?
    #40