Info Latest project - 1971 Kawasaki 175cc F7

This is my latest project for restoration, a 1971 Kawasaki 175cc F7 that I found hiding in a shed when I went to pick up some spares for my blue Yamaha YB100.


Poor thing has had some abuse in it's life, but it is only showing 10,000km on the clock and the condition of thing like swingarm bushes, cables, fork bushes, etc suggest that this is genuine. The shed where I found it had had a flood go through it with a dirty water 'tide mark' up to the bottom of the carb, and having no back wheel it was sitting in the mud as well. No idea what happened to the back wheel, but they are not too hard to find on evilbay. Have ordered a few new bits already and stripped it down to get the frame sandblasted ready for some new black paint. This will be the last of my Kawasaki 175cc Trifecta. I now have a 1966, 1971 and 1981, one from each decade.

 

What, all of it. Will watch you in Tenterfield on the 18th (licking of plate opitional).

Phil, already done the chips for the how to with weather seized piston.

 

Sorted through all the bits to be painted black today. I like to have all the bits ready and have a 'painting day' to get them all done at the same time, so I only have to clean the spray gun once. Sat down with the wood chisel again and started scraping off 44 years of built up crud. Have left some bits soaking overnight is a bucket of petrol.

 

A new (second hand from wreckers) rear wheel arrived yesterday and spent today stripping tyres off, brakes and bearings out, and removing the spokes so I can repaint the hubs and lace up the new spokes and chrome rims. Had to use a bit of heat from the blow torch on a few of the nipples and only broke one that refused to release.

 

So we have wheels again.
Parts laid out ready to assemble. There are 36 spokes in most wheels, 18 per side with inner and outer bends on the ends.

Fit spokes to hub from both sides.

Put the spokes into one side first. I oil the threads and just do the nipples up a few threads to hold them.

With both sides in I put a bit of tape across four spokes in each quarter and tighten them enough to hold the rim in place.

I then mount the wheel into the jig and tighten/loosen those taped spokes to get the rim centred.

Using a pointer clamped to the jig I can get the runout sorted.
I don't bother with a dial gauge as some do, within 1/2 mm is good enough for a trail bike (tyres aren't that straight anyway). Then I go around and tighten the spokes in between, all the time checking that the runout is still good, until a final tighten on all spokes to tighten wheel.

Some spokes will protrude through the nipples and will need a touch of an angle grinder to remove.

Tyre and sprocket mounted ready for a bike.

The front is done too, just waiting for new bearings to be fitted.

 

Got the frame and all the little pieces painted black today. Couldn't wait and fitted the toolbox.

 

Have not done a lot lately (with being away for two weeks and bad flu for four weeks) but have managed to bolt a couple of bits together.



Have been working on welding up holes in fuel tank, but will still seal it to be sure.
Wiring is all sorted now, just waiting on new headlight lens and indicators.
Will start on engine when feeling a bit better.

 

Monday was clear and warm so went and bought some paint and had a day with sandpaper and spray gun. Fitted the stickers today and bolted on the guards.

Engine is soaking in a big bucket of degreaser to soften the 40+ years build up of crud.

 

Have rebuilt the gearbox and fitted to the frame. Chain, carb, cables, wiring, etc all in but have come to a bit of a hiccup with the barrel. The rust in the bore above the stuck piston is so deep that I need a 2mm oversize piston. These are unobtainable so far as all those who list them (wiseco, prox, etc) have no stock and are not going to get any more. JP pistons in South Australia will make them, but want a minimum order of 10, at a cost of over $1,000, and what do I do with the 9 others pistons as there cannot be that many people out there wanting 1970's trail bike piston.
Ebay list a NOS barrel and piston set for $500 +$100 shipping, and several used barrels for under $200 but they will need reboring and new pistons too.
Will play with another bike while I search for an answer.

 

Have a bit more done.

 

Have been working on the seat rebuild this week.
The 'tin worms' had been into the side rail on the down hill side where I found the bike. Fortunately the rest is not as bad as the Yamaha YDS-5 I did last year, so some new side bits needed to be made.

These I cut and folded from some 1.2mm sheet, then 'crinkled' them to form a curve to match the seat shape.

The shorter piece to the rear of the seat needed a much tighter bend. This I 'crinkled' severely to get the right bend, then tacked a piece of heavy welding wire to each end and heated and flattened to fit snugly to the seat base.

I cut the rusted bits off with the plasma cutter. When finished welding into position I blasted the seat and painted. Sat on frame to check alignment.

With some repairs to the old foam and a new cover fitted it looks ready to ride.

Have found a second hand barrel from a VJMC member in Melbourne which should be here next week. Still need to get a piston and the muffler heat shield rechromed.

 

No, I'm waiting to see you eat your dinner?