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Old 10-29-2011, 04:21 PM   #1
johnnyc14 OP
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Joined: Mar 2008
Location: St. Albert, Alberta
Oddometer: 205
Kawasaki A7 Avenger 350

I've been looking for one of these for a while, they are pretty scarce here is western Canada. I bgought this 67 A7 and 2 A1 250 cc Samurai's. The A1's are parts donors but I may be able to get a complete A7 and an A1 out fo this lot.I had an A1 when I was a kid and it was the best of my early bikes. This one runs and is very complete. Another project for winter.



Check out the pipes on this one!! ;D


The tank on the A7 is in really good shape, hardly any rust. The paint under the chrome panels is like new and will make a great reference for matching the color. Another A series owner from New York had some good rubber knee pads and they are on their way to me in the mail.



The engine is in remarkable shape. It really just needs cleaning up and new rings, gaskets and seals. These rotary valve twins must have been much more expensive to manufacture than the piston post 2 strokes. Lots more parts and machine work involved.






[IMG]
http://i168.photobucket.com/albums/u...P8310268-1.jpg[/IMG]

Lots of spooge but not too bad considering its 44 years old.

The frame is ready for sandblasting and I have already glass beaded the cases, cylinders and heads


Lots of nights in the garage ahead. Sure beats spending all winter watching TV.
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1971 Honda CL450
http://advrider.com/forums/showthrea...ight=johnnyc14
1972 Kawasaki F9 Bighorn
1973 Kawasaki H1D Mach III
http://advrider.com/forums/showthread.php?t=634816
1974 Yamaha DT250
http://advrider.com/forums/showthrea...ighlight=dt250
2003 Suzuki DRZ400S
2008 Kawasaki ZG1400
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Old 10-29-2011, 04:47 PM   #2
concours
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Outstanding! Keep us in the loop!
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Old 10-29-2011, 05:56 PM   #3
subagon
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Location: Antioch, FL
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I don't know anything about old Kawasakis, but saw this trio for sale last year at Barber. Maybe you can ID them?



Full sized image here

Love that old logo

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Old 10-29-2011, 09:24 PM   #4
anonny
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Nice, real nice... how are they to find parts for?
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Old 10-30-2011, 05:40 AM   #5
johnnyc14 OP
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Location: St. Albert, Alberta
Oddometer: 205
Subagon, it's hard to identify the 2 closer bikes but I think they might be 1965 Roadrunners, 175cc. The one behind I believe is a J1Tl 85cc. Kawasaki did not have a toe in the door of the North American market until 1966 and all those bikes are older than that.

Anony, they are a little more difficult to find parts for than some of the others I've worked on but I was lucky to find the 2 parts bikes. A lot of the rubber parts are the same as early H1 stuff. Engine gaskets, bearings and seals are no problem but good exhaust pipes and oversize pistons are almost impossible to find. I have 2 sets of pipes that are probably repairable but it will be a lot of work. After they are repaired nobody wants to re-chrome 2 stroke pipes because the oil in them contaminates the chroming tanks. I have a pattern for expansion chambers so I might make some pipes and get them ceramic coated.

The air filter element on all 3 of these bikes is un-usable.I did some research on the K&N filter site and found a filter that is just a little taller than the original but will still fit into the original housing with a minor modification.
The original filter has a metal base glued onto it that fits tightly into the base of the filter housing bottom. I soaked the bottom of the original filter with solvent and removed that metal base.






I used my die grinder to remove the depressed center of the original top housing to add about 5 mm of height and make room for the K&N filter.





I bought a K&N RX-4010 air filter at a local auto parts store for $50. I guess the tuner car guys use them because they had lots in stock.







I used a utility knife to remove the rubber flange from the K&N and trimmed it so it will fit into the original base of the paper filter.





I test fit the base to make sure it will fit the original filter base, then cleaned both surrfaces with acetone then glued them together with good quality RTV silocone sealant.










Then I let the silicone set up for a few hours. It fits perfectly and should flow better then the original.















Here you can see that the top of the filter element breathes too unlike the original. I'll have to be careful when washing the bike!

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1971 Honda CL450
http://advrider.com/forums/showthrea...ight=johnnyc14
1972 Kawasaki F9 Bighorn
1973 Kawasaki H1D Mach III
http://advrider.com/forums/showthread.php?t=634816
1974 Yamaha DT250
http://advrider.com/forums/showthrea...ighlight=dt250
2003 Suzuki DRZ400S
2008 Kawasaki ZG1400
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Old 10-30-2011, 05:49 AM   #6
LasseNC
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Location: Denmark, Danimarka, Danmark, Dänemark
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Rememer to re-jet! :) Looks good, what are you planning to do with the glassbeaded parts? It will be a b*tch to keep in somewhat clean shape if left untreated.
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Old 10-30-2011, 06:06 AM   #7
JonnyCash
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Quote:
Originally Posted by LasseNC View Post
Rememer to re-jet! :) Looks good, what are you planning to do with the glassbeaded parts? It will be a b*tch to keep in somewhat clean shape if left untreated.
I glassbeaded all my engine casings on my RD a couple of years ago, and left them bare. They still look great. I've heard people say that this is a concern, but I'm left to wonder why. The way I understand it, glassbeading peens the pores of the castings closed, and makes them easier to keep clean, and in my experience, it seems to work.
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Old 10-30-2011, 06:09 AM   #8
johnnyc14 OP
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Everything get painted with engine enamel then baked at 250 degrees F for 2 hours. This is my H1 engine in progress. I've used this process for many projects and the paint is very durable. The A7 engine was completely painted from the factory so there will be no polishsed covers like the H1





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1971 Honda CL450
http://advrider.com/forums/showthrea...ight=johnnyc14
1972 Kawasaki F9 Bighorn
1973 Kawasaki H1D Mach III
http://advrider.com/forums/showthread.php?t=634816
1974 Yamaha DT250
http://advrider.com/forums/showthrea...ighlight=dt250
2003 Suzuki DRZ400S
2008 Kawasaki ZG1400
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Old 10-30-2011, 08:23 AM   #9
vicster
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Nice find on the Avenger. I wanted one of these when they were new, and have been looking for one off and on the last couple years. Love the old two stroke street bikes.
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Old 10-31-2011, 06:27 PM   #10
johnnyc14 OP
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Got some work done on the suspenson. New fork seals and o-rings, some NOS top fork bolts and washers and some 30 weight fork oil(hard to find that stuff).





Re-assembled.



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1971 Honda CL450
http://advrider.com/forums/showthrea...ight=johnnyc14
1972 Kawasaki F9 Bighorn
1973 Kawasaki H1D Mach III
http://advrider.com/forums/showthread.php?t=634816
1974 Yamaha DT250
http://advrider.com/forums/showthrea...ighlight=dt250
2003 Suzuki DRZ400S
2008 Kawasaki ZG1400
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Old 10-31-2011, 06:31 PM   #11
johnnyc14 OP
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I got the frame sand blasted and I primed and painted it. Powder coating is not in the budget on this bike.





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1971 Honda CL450
http://advrider.com/forums/showthrea...ight=johnnyc14
1972 Kawasaki F9 Bighorn
1973 Kawasaki H1D Mach III
http://advrider.com/forums/showthread.php?t=634816
1974 Yamaha DT250
http://advrider.com/forums/showthrea...ighlight=dt250
2003 Suzuki DRZ400S
2008 Kawasaki ZG1400
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Old 10-31-2011, 08:56 PM   #12
anonny
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Quote:
Originally Posted by johnnyc14 View Post
Powder coating is not in the budget on this bike.

You really need to do your own powder coating, it will pay for itself on the first bike. Want to borrow my spare to see if it's for you?

Nice solution for the air filter, looks nice and is functional and stock looking.

Care to measure the ID at both ends of those fork boots for me, I need some for my CL.
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71- 450 Honda CL re & re

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Old 11-01-2011, 06:10 AM   #13
johnnyc14 OP
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You're right I really should get into the powder coating. I'd like to try the powder coating Bake but I don't have a big oven, I just have an old toaster oven I use for the small parts. What do you use? Where did you get your PC gun and supplies? It would be really cool to have an oven big enough to do a frame in.

I will measure those foprk boots and get back to you.
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1971 Honda CL450
http://advrider.com/forums/showthrea...ight=johnnyc14
1972 Kawasaki F9 Bighorn
1973 Kawasaki H1D Mach III
http://advrider.com/forums/showthread.php?t=634816
1974 Yamaha DT250
http://advrider.com/forums/showthrea...ighlight=dt250
2003 Suzuki DRZ400S
2008 Kawasaki ZG1400
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Old 11-01-2011, 06:27 AM   #14
lrutt
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Location: Deltona, FL
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I disagree, I say stick with paint. Rattle can Rustoleum. Easy touchup, cheap, and more closely resembles the original.

- Can't touch up PC if it gets nicked up etc.
- Once it starts to lift with corosion underneath you have a mess
- More difficult to apply etc.

Unless you need uber chemical resistance, I don't see the advantage.
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Old 11-01-2011, 10:16 AM   #15
Sniper X
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Love the A7. I am always looking for a deal on an old school 2 stroke street bike.
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