Kawasaki Triples Club

Where did you get the ears? I don't know anyone that does repro fork ears for S series, apart from maybe dodgy Indian eBay ones.
Z1/900 ones are available but have larger diameter legs and shorter ears.

Yes I made the mistake of getting the dodgy Indian ones as mine were unusable. They are actually for a KH400 in chrome as I couldn’t get the right ones. I don’t mind the Chrome but everything about them is rubbish.
They are longer than the old ones , the top washer doesn’t fit over as its meant to as the material is thicker with the Chroming, the headlamp location relative to the tube is different (lower) and the indicator stalks wont go through the holes.
So…. I had to cut them down in length plus a bit more to allow for the top washer not fitting over properly. Had to clean up the inside as there were lots of burrs. Now I have to enlarge the holes for the indicator stalks to fit through…….
So as I’ve had to butcher them I expect they will rust now.
Maybe I should have tried harder to get hold of 2nd hand ones. I still have the old ones so maybe I’ll have a go at repairing them. I’ll need to brush up my welding or other wise use fibreglass……
I can always change them later for correct ones.

Phil

I'd get the old ones half decent with bit of filler , paint them black and use them until you find the correct ones. The S range flipped back and forth between black and chrome so they won't look desperately out of place.
You can spend (waste) loads of time pontificating on details like this when really your time is better spent just getting on with it and getting it finished.

Summer has arrived, get out there and enjoy it !!

Just about to order exhausts from Higgspeed.
Should I order the S2 ones 1972-3 or the S3 ones as my bikes an S2A ….?

Phil

S2 Phil
The S3 is a different mounting to the cylinder.
S2/S2A are the same.

Thank you

Goalhanger wrote: ↑Sat May 07, 2022 10:51 am So as I’ve had to butcher them I expect they will rust now.

Paint any cut edges with clear nail varnish. Did this on my KH500 (Z1 repro) yoke covers years ago, and still look good.
.

Ok, so wiring all correct and everything working. Just need to tidy routing now. Headlamp on and clocks.
So I started to true up the wheels starting with the rear. All went ok except I’m not sure of the LHS locknut. Should the washer go on before the nut or after - as the parts manual shows…?
Also is there a washer on the shaft nut ? Not showing one on the parts manual. My bike has the shaft with the hole through the end so only one nut which goes on the LHS of the bike.
Thanks
Phil

Should say none of the nuts/bolts is tightened up yet.

Another issue - the torque arm has a single thickness one and and double at the other. Am I right I’m presuming the double goes on the frame fixing ? And if so which but goes inside the 2 frame lugs? Attached a picture of the frame fixing. Ta
Phil

Just some pics of the build so far inc my basic wheel mount for truing and balancing.

Another day…. I just fitted the clutch cable and levers and adjusted the clutch actuation arm but I’m not getting any movement on the clutch whatsoever ……
Have I done something wrong? I’ll put this on technical issues as well.
Ta
Phil

Hi Wolfie , I’ve replied on the Technical forum.

Cheers
Phil

While I’m waiting in my new clutch pushrods I’ll be getting on with repainting the seat base and other bits and pieces.
I need to put the engine breather on - but haven’t got a picture of where it went . Can someone point it out fir me please ? I’m guessing RHS hole that is open to the internals but the pipe and little connector is too big for that hole ….

Ta

Hole at the back of the rear upper engine mount, adjacent to sprocket.

Ah ok I see is it this one ? And what about this one ? It appears to be open to the gearbox or maybe I’m mistaken ?

Hi Phil,

Yes the hole in the first photo, how the rest going?

Regards Gary

Sorry, the second photo is drain holes which should be clear to allow two stoke oil and petrol to drain away should any of these leak and collect in this well.

Regards Gary

GWB wrote: ↑Sat Jun 04, 2022 3:33 pm Sorry, the second photo is drain holes which should be clear to allow two stoke oil and petrol to drain away should any of these leak and collect in this well.

Regards Gary

and water......although who goes out in the rain these days

Not me

Regards Gary

Thanks guys, appreciate your help. I just didn’t take enough photos when I was stripping it down.
Just painting seat base and cleaning chrome trims up. Found that M3 bolts go in the chrome trim and I’ll glue them in so I can tighten up the nuts once assembled.
Thanks
Phil