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1972 Kawasaki H1B Restoration

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

  1. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    We are getting there. This weekend concentrated on the electrics. The wiring harness was completed and installed. The points and condensers were replaced and the timing set. Here is a pic of my battery of choice, Anti Gravity. I love the Lithium batteries because you can toss your Battery Tender, no vent tube, no acid stained exhaust, no refilling the cells, less weight, and you can mount it anywhere anyway. This battery has way more punch than this bike needs but I had it on hand and it fit nicely. Oh, and here is a nice plus, Anti Gravity is a MADE IN THE USA PRODUCT!!!

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    #61
  2. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    I forgot how much I hated points and have been spoiled by CDI. There should be a required class in high school to teach patience, around the Sophmore Year called, "Multi Cylinder Points Installation" No easy distributor stuff, just points and timing. If you are one of those folks who thinks that technology has gone too far, grab a bike with 3 sets of points, you'll change your mind. Here is a pic of a half days work setting points with a cylinder dial indicator. The timing was so far off on this bike it scared me a bit. But then I noticed all the screwdriver marks and remembered that this is a points bike so screwing around in the ignition cover is common place. Oh, did I mention how much fun it is to find those little circlips they put on these bikes on the floor? Good news is, after test, all 3 cylinders are sparking a nice Blue.

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    #62
  3. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    The front brake problem got addressed too. The kit I used to rebuild the caliper was a Kawasaki components kit. I figured that would be better kit than an aftermarket? I ended up getting a K&L kit like all the others I've used and it worked fine, no leaks.

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    #63
  4. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    The bike came with an extremely rare "Bailing Wire" Battery Door. I felt it needed more of a stock look so an NOS door was installed. The Antigravity battery kit comes with foam in different thicknesses that are used to secure the battery in the box once the door is closed. I did go a little more high tech with a plug in fuse holder that lined up pretty good with the old glass tube type hanger on the door. Purists be damned, those points pissed me off and I'm adding some 80's technology here!

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    #64
  5. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    A wiring harness pic here. I admit I cheated on this one because nobody sees it, but I still wanted a clean look. The OEM coil mounts were Yellow Chromate but I didn't want to go thru the plating process and then Chromate. I ended up wire wheeling them clean and then Yellow Chromate, which came out just fine. Connectors were replaced and the rubber boots got the Back to Black treatment.Turns out I think I found out why this bike got parked back in the late 70's. The center cylinder coil wires had chafed thru against the clutch cable and the center cylinder must have stopped firing. Simple fix but it was peobably one of those deals where the bike gets parked with all good intentions of getting to it and 35 years go by.

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    #65
  6. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    A few pics of how she sits now. All lights, horn, etc. work. All three plugs spark so this bike is getting close to blowing smoke. I will be traveling next weekend but the time table looks good for Deals Gap in the beginning of May.

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    #66
  7. Kamala

    Kamala Long timer Supporter

    Joined:
    Oct 4, 2005
    Oddometer:
    13,711
    Location:
    Nashoba Valley
    Impressive build! The detail works puts you in the Michelangelo class! :clap
    #67
  8. RickS

    RickS Long timer Supporter

    Joined:
    Dec 12, 2006
    Oddometer:
    1,792
    Location:
    Altus, OK
    Nice. Very nice!
    #68
  9. anonny

    anonny What could go wrong?

    Joined:
    Mar 20, 2007
    Oddometer:
    6,830
    Location:
    Beautiful Revelstoke BC
    Very nice. Best way to set a triples timing is with a dial gauge.
    #69
  10. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    Back at it again this weekend. I have family obligations so not as much as I would have liked got done. I guess I could have snuck out early. "Hey Mom, I know it's your birthday but I got a build coming together". This weekend was a dirty one cleaning and polishing cases. The cases need to get done before I can move on to starting the motor and getting foot controls hooked up. It is a thankless dirty job, but pays off big with lots of pop. These cases were cleaned in the parts washer, then bead blasted, then scrathes and mars were blended out, re-blasted, sanded to 600 Wet, Tripoli polished on a sewn wheel, and then Jewlers Rouge on an open wheel. Here is a before pic. A buddy stopped by today and saw them before and commented about how crappy they looked.

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    Here is the clutch side cover after being cleaned, bead blasted, and then having the brake pedal marks and some other scratches blended out with a 2" Medium Scotch Wheel. The marks came completely out. The Points Cover had a nice dig that I didn't know if it would come out completely but it did and you would never know where it was.

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    Here is the after pic.

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    For the lettering I use a hi temp gloss black paint and a pencil thin artist brush. I also have a teeshirt rag stretched tight on a sanding blocking dampened with Aceytone in case there is a screw up. I do have a secret weapon that helps with a steady hand on the artist brush, and here is a pic of that too. Just a little is all you need. Too much and you forget you are building a bike and head off to the local Tittie Bar.

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    #70
  11. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    The clutch cover got mounted with oil pump and tach drive. The NOS rear brake pedal got installed with cable, and the foot pegs went on. These are Stat O Seals that are used on the oil pump banjo fittings. They replace the Aluminum washers that come stock and are a one time use seal. These seals have a rubber lining and can be reused. Many pumps get ruined from stripped bolts or have leaking lines from reusing the original washers.

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    A mistake I have made before is mounting the pump before attaching the cable to the case. It is a real biatch to do it after the pump is on.

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    If you can get NOS it is usually as expensive as a rechrome but you don't have the lead time. The brake lever and shift lever are NOS. The K/Start is still in good shape and will be reused. Since most of these bikes had common brake and shift levers there is still a few out there.

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    #71
  12. Scoobynut

    Scoobynut Been here awhile

    Joined:
    Aug 26, 2009
    Oddometer:
    933
    Location:
    SW N. Dakota
    Awesome build, coming together very nicely, I'll be following this one. Now if you'll excuse me, I have a date with some Jagermeister and the tittie bar. :evil
    #72
  13. sprouty115

    sprouty115 Long timer Supporter

    Joined:
    May 29, 2012
    Oddometer:
    7,809
    Location:
    Providence, RI
    Very well done!
    #73
  14. MikeGayner

    MikeGayner Been here awhile

    Joined:
    Jan 4, 2014
    Oddometer:
    178
    Location:
    New Zealand
    You are a true artist, I'm speechless. Great work.
    #74
  15. Reverend12

    Reverend12 Well there it is..

    Joined:
    Nov 21, 2008
    Oddometer:
    1,527
    Location:
    Classified
    That..is a Thing of beauty!
    :clap
    #75
  16. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    Time to wrap it up. The gas tank components were installed this weekend. I wrap the tank in an old Tshirt, for this tank an 08 ISDE Tee that got ruined from bleach will do. A 6" X 1/8" drill bit is used to ream out the cap mounting holes that get filled with paint. The extended bit is needed to keep the drill chuck away from the tank. A small file is used to remove the paint in the areas where the cap and clip mount. In this pic my finger is pointing to the rivet on the clip. The rivet has a small dimple on one end. I take an old steering head bearing, yea, they are still good for something, and use it in a Vise Grip to expand the rivet. It works very well.

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    #76
  17. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    Some before and after shots of the petcock. These petcocks are vacuum activated and I like them because you don't have to remember to turn off the gas, and in a 2 stroke that is a good thing. First pic is a before with the rebuild kit and an after pic. The petcock gets the same soak overnite in carb cleaner and then a quick acid dip in Muriatic Acid as the carbs got.

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    #77
  18. przjohn

    przjohn Been here awhile

    Joined:
    Aug 14, 2008
    Oddometer:
    259
    Location:
    Ellington, CT
    And now for the bittersweet moment, the end. The bike fired right up and has been run about 2 miles up and down the road. I will be taking it to the DMV this week for registration and hope to have, (if this Winter ever ends) a couple hundred miles and the hidden Gremlins worked out for Deals Gap first week in May. I don't know if it is Porsche Dave's crank work but this has to be the smoothest running triple I've done. As of now, (anyone who has a vintage bike knows what I mean by that) everything works. All lights, horn. brakes, motor, is working pretty damn well.

    May I say first, this bike is a Looker! The Orange color, Larry got it perfect, Thanks again Larry. Tom, thank you for the bike, it will be on it's way to your house with a favorite screwdriver of yours in the very near future. I can't wait for you to see the bike and take it for a spin.

    To all who have followed this thread, thank you. So, God willing, until next Winter and a project still to be found, my finished pics.

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    Where Mice once had a pretty good home.

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    #78
    Tammy likes this.
  19. JAB

    JAB Unsprung Weight Supporter

    Joined:
    Dec 2, 2004
    Oddometer:
    1,712
    Location:
    Beautiful Monrovia
    Nice build. Here's to many miles of 3 cylinder music. Enjoy.
    #79
  20. PlainClothesHippy

    PlainClothesHippy Only dimly aware of a certain unease in the air.

    Joined:
    Jan 19, 2014
    Oddometer:
    3,920
    Location:
    Lancaster County, PA
    :clap Thank you for sharing this. :clap
    #80