Kawasaki Triples Club

Before tank is fitted up and petrol pipes etc…

Oil pump cable adjusted to align marks. The little ear that folds over the nipple fell off so I had to just crimp up the end of the track part so the cable/nipple can’t come out.

A little grease on each end of the air tubes may help installation.
You are likely to have air leaks at the oil pump connections without using Dowdy seals.

I bought Dowty seals but my existing bolts are too short to take them

Hi Phil,

Form what I can see in your photo's she's looking gorgeous and not far off your first ride, you must be so pleased with all your hard work.
As said in another post (Treeman) one more triple saved which I would like to thank you for and involving all of us KTC member's with your posts/build, great stuff and looking forward to hearing + photo's about your first ride.

Gary

Goalhanger wrote: ↑Thu Jun 23, 2022 6:25 pm FB302881-FB52-4074-9578-B01A3C6F28A0.jpeg

They look very thick for dowty washers

Hi

This bolt is longer than the 3 outlets :

As you can see from my last photo the Dowty washers I bought are too thick to go on with the existing bolts. Is it such an issue that I need to try to source longer bolts??
I seem to recall the Dowtys being too thick being mentioned on the forum before.
At least it’s pretty simple to take the cover off and fit them later.
Also, oil hose clamps … do you use them or are they ok without? If I need them where can i source them?
Thanks again
Phil

So I’ve ordered double spring hose clamps for the oil lines.

But still can’t get the air inlet hose in. I’ve boiled it up for 30mins so it’s soft but it just won’t go on. Plus it looks like when it goes on it’s too short to go in the air box.
Does the carb have to be slid along the inlet manifold to make it reach …
Ta
Phil

Try inserting the boot in the air box first... don't forget the clamp.

Those dowdy seals are too thick... not normal. Try another source. And yes, it will be an issue if new alum seals or dowdy's are not used.

I’ll give that a go .
I’ve seen that I can get the clamp on afterwards.
I needed a break so indoors having a coffee….
Exhausts here today

Phil,
I had a few oil pump problems but I got my 6mm dowty washers from here:
http://www.earls.co.uk/
They were cheap (about 20p each).
I don’t think there’s anything wrong with your banjo bolts.
The longer ones are for a inlet and the shorter ones are the outlet to the oil lines.
They are still available from Cradley Heath Kawasaki.
Without giving you eggs to suck be very careful when you tighten them, it’s easy to strip the pump thread.
In your photo it looks like numbers 1, 4 & 5 are outlets. Not sure about number 2. 3 & 6 appear to be inlets, but as all are crucial you might want to replace them.
Hope that helps,
H.

Hi Herbert. The picture of the bolts isn’t mine. I will take a look at the link you sent , thanks.
At least it’s easy to get at .
Ta
Phil

Hi Herbert, I followed the link and I see the Dowty washers and also the Stat-O-Seals. It actually says in the description the Dowty is thicker. But the Stat-O-Seals look thinner as it says to replace copper crush washers. Might drop them an email to see if they can tell me the thickness.
How did you get on with the Dowty washers with standard length bolts?
Thanks
Phil

I guarantee that Stat-o-seal will work with OEM bolts. 1/4" will work for both tank line & case lines... metric will not.

Brill thank you

Finally managed to get the piston out of the caliper…
Yay…

Looks like a good result there. Clean up, new seals, stainless piston and you should be good to go

Goalhanger wrote: ↑Fri Jun 24, 2022 5:22 pm Hi Herbert, I followed the link and I see the Dowty washers and also the Stat-O-Seals. It actually says in the description the Dowty is thicker. But the Stat-O-Seals look thinner as it says to replace copper crush washers. Might drop them an email to see if they can tell me the thickness.
How did you get on with the Dowty washers with standard length bolts?
Thanks
Phil

Absolutely fine..... but mine is an H1 with a very slightly different pump. (Only inasmuch as the pump cam turns in the opposite direction, I believe the pump bodies are the same).

Tony_d123 wrote: ↑Fri Jun 24, 2022 9:10 pm Looks like a good result there. Clean up, new seals, stainless piston and you should be good to go

Or stop.

Caliper internals ordered. Oil pump washers to be ordered tomorrow.
Fitted exhaust today. Had to bend centre exhaust bracket as exhaust touched my 4” tyre. So had to space out RH exhaust so they didn’t touch. Spaced out LH exhaust with a similar spacer. Pics attached.
I do need to fit the exhaust springs …
Phil