Author Topic: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.  (Read 50177 times)

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Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #400 on: September 26, 2020, 06:09:12 PM »
I remember when the Motor Officers had KZ1000's and with those and Motorola,not many folks were able to out-run them anywhere.
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Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #401 on: September 27, 2020, 05:47:26 AM »
I did get chased by a motorcycle cop when I was 18, but to be fair, I didn't know he was chasing me? I was riding my shiny new CB750F back from my home town 200 miles east of Melbourne, when I pulled up at (one of the few) sets of traffic lights in a town called Traralgon. In the lane next to me, was a young guy in a 1967 HR Holden with what sounded like a hotted up 6 cylinder engine. (Holdens, Aussie built GM cars didn't get V8's until '68) He was blipping his accelerator pedal, the universal language for challenging someone to a race, so I accepted, by blowing him into the weeds.

I kept going, it was early morning and a bit foggy. Up ahead I could see flashing blue and red lights, and the traffic had stopped. Turns out there was a multiple car crash ahead. I was sitting on my bike when a cop on an F2 pulled up beside me. I said, "G'Day", and he said, "Get off your fcuking bike!". Ooops. It turns out that he'd been following me from the street light drag race, and was none too happy with me. He said, "Show me your license!" I replied, "I've only got a learners permit" He then said "Well where's your fcuking L Plate?" (I was required to have a yellow plastic square about 6 inches by 6 inches with a black "L" on it) I replied, unconvincingly, "Er, it must have fallen off?"

He exploded. "You only have a learners permit, you don't have an L plate, and you were doing speeds in excess of 180 KPH (112 MPH) in a 60 KPH (35MPH) zone??? Hmmnnn, things weren't going well. He said, "What do you do for a living?" I said, "I'm in the Army". His whole demeanor changed. "Army eh? I was a grunt in Vietnam!" I took a look at his uniform, and under his bike jacket I could see that he was wearing his Vietnam ribbons and combat badge. He said, "Allright son, this is what we're gonna do, we'll drop it to 130 KPH in a 100 KPH zone, you won't have to go to court, you'll get a fine, and you'll keep your learners permit.

He was a Senior Constable (2 stripes) so I said, "Geez thanks Corporal!" (in these situations a bit of sucking up never goes astray) When I looked up at his face, he was positively beaming. The traffic had started to move again, so he said, "Off you go then digger, and behave!" I promised I would, then rode off feeling slightly chastened, but not as badly off as I'd expected. I ended up receiving an $80 fine in the mail which back then was a lot of dough, over a weeks pay, but if not for his kind gesture, I would have been in very deep sh1t.

I always wondered though, why he told me I was doing "Speeds in excess of 180 KPH", until only a few years ago I bought a cop speedo on Ebay, and found out that it only went up to 180 KPH! I suppose back then not a lot of cars could go over 112 MPH, but of course big jap bikes were still pretty new, so the police technology hadn't caught up, not even on their own bikes. Lucky for me, my speedo said I was doing 215........ ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #402 on: September 27, 2020, 10:38:40 AM »
Well Terry,you made sure to blow-off the fellow driving the HR Holden,and then some.. trying to humiliate the poor fellow so he'd never challenge another CB750 ??  :) The situation with that Policeman turned-out in your favor !
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline jgger

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #403 on: September 27, 2020, 11:53:37 AM »
I had a simular one just after they dropped the max speeds to 55 mph here in the states. I was going from So. Cal. to San  Jose  minding my own business at 105 mph. I was apparently involved in a high speed chase that I didn't know was going on. 105 in a 55 is automatic go to jail invite. Lucky for me the cop also owned a cb750, so we shot the crap about bikes for about 30 minutes and he wrote me for 65 in a 55. I was ok with that!
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Offline spotty

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #404 on: September 28, 2020, 04:45:26 AM »
i once accepteda challenge to get from a friends house to my place in under 15 minutes , it was probably about 20 miles and i didn't really stand a chance but i was up for it ( it was greensborough to hawthorn for terrys reference )

did i mention i was on a vespa...

got about a third of the way and not surprisingly got pulled up by a quite irate gentleman who had some very pretty blue lights on the roof of his shiny white car. he claimed to have clocked me at about 160kmh in a 60 zone ( 100mph in a 35mph zone ), which i found a little hard to believe as i was , after all, on a vespa. however he was adamant that that was the situation but the kicker was he was just going between cop stations and didn't have his ticket book so he wasn't going to book me

this was of course a good thing but having a ticket saying 160kmh on a vespa would have been a great thing to have, i could have shown it to my cellmate as that was a very lockable-up kind of offence

it was a much slower ride home after that 
i blame Terry

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #405 on: September 28, 2020, 04:57:19 AM »
Thanks guys, the fastest I've said that I've been on a bike was 270 KPH (169 MPH) on my Honda VTR1000R (RVT1000R in the US) SP-1, and a peanut here from Germany questioned my integrity, suggesting that only in Germany did they have "Autobahns" that could carry that sort of speed, not realising that Germany will fit inside Australia 22 times, and the Hume Freeway (local to me) is only 60 miles short of Germany's longest Autobahn, and just as wide. Of course I'd never ride at those sorts of speeds on public roads, because that'd be illegal, and "legal" is my middle name......... (besides "safety", of course) You have to laugh when people think they know what they're talking about, when they're talking out their arses......

Anyhoo, yesterday was a much nicer day than Saturday. If I'd known just how good, I'd have put 5 litres of gas in the F2's leaky tank and gone for a ride with the Dyna coils to see how much better the ride was, but instead, I attacked the 1428 engine, as I need to move that bike out of the sheltered workshop, so I can start on the Z1. I cleaned the gasket surfaces on both the head and the Arias cylinder block, and sprayed a nice heavy coat of copper gasket spray on the copper head gasket to (hopefully) ensure a nice tight seal. I let it dry to the point where it was just slightly "Tacky" then dropped the head back in place.

But I'm getting ahead of myself. First I had to helicoil 5 of the 16 camshaft saddle bolt holess, as the sad thing about DOHC engines running big cams and heavy springs is that the puny 6mm screws strip out very easily when you go by the book to  lock the cams in place as per the OEM manual, when setting the cam timing.

1428 head job 27 Sep 2020 1 by Terry Prendergast, on Flickr

That was fine, and I dropped the head in place, and after torquing down the head to 30 foot pounds in 10 foot pounds (or "pounds feet", whichever way you pronounce it) increments, was very proud of myself for getting the cam timing spot on, on the first go. Keeping in mind that I haven't checked the valve clearances yet, I set the APE top cam chain guide in place, but didn't loctite it as yet, as because it has the more desirable "Shim under bucket" valve adjustment arrangement, once you work out what size shims you need, you need to remove the cams to lift the buckets, to replace the shims. I bought a 13mm shim kit so I have plenty of shim options, so hopefully I won't have any problems giving myself around 5 thou clearance on both the inlets and exhausts. 

1428 head job 28 Sep 2020.jpg 1 by Terry Prendergast, on Flickr

I didn't have to "clearance" the head for the Norris .425 lift cams, but it was close. Hopefully, not too close.

1428 head job 28 Sep 2020.jpg 2 by Terry Prendergast, on Flickr

As you know, I had to wait 6 weeks for the APE cam chain guide. The OEM GPZ1100 head's cam chain guide is just a rubber block, held in place by a couple of cast in alloy studs.

1428 head job 27 Sep 2020 5 by Terry Prendergast, on Flickr 

To make it work with the custom APE guide, I had to "mill" out the cam cover to make room for the APE guide. With a dremel tool fitted with several burrs, my Makita 20,000 RPM die grinder and a hand held "finger sander", it took around 90 minutes to just get enough clearance. Once again, APE could have engineered it better, rather than expecting that all their customers would have the tools required to make it fit. I like APE stuff, but in this case, they've chosen form over function. Oh well, 90 minutes of my time as opposed to 1 minute on one of their CNC mills is no biggie, in the grand scheme of things. I did finally get the cam cover off, even though it's probably paper thin now...........

1428 head job 27 Sep 2020 6 by Terry Prendergast, on Flickr

The Kawasaki production line is looking pretty nice though, I gotta admit. More soon. ;D

1428 head job 27 Sep 2020 8 by Terry Prendergast, on Flickr





     
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #406 on: September 28, 2020, 02:14:32 PM »
Will that rubber block have enough metal up-top to fully support it for strength ?
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #407 on: September 28, 2020, 04:37:50 PM »
G’Day Bill, no, with the custom APE top camchain guide the rubber block is no longer required, it was Kawasaki’s answer to the need for an upper guide on the GPZ engine when it was running a Hyvo camchain, so it’s now redundant. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #408 on: September 28, 2020, 04:59:28 PM »
Terry,
I wonder how one of those engines would do in a small mini-car like the 70's Honda 600 or one of those tiny European automobiles ? I know they're air cooled so that would be a problem
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Tintop

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #409 on: September 28, 2020, 05:10:35 PM »
Terry,
I wonder how one of those engines would do in a small mini-car like the 70's Honda 600 or one of those tiny European automobiles ? I know they're air cooled so that would be a problem

I'd go for a VFR1000R for an S600 or 800 swap.  Kind of like a baby Lancia. ;D ;D
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Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #410 on: September 28, 2020, 05:21:01 PM »
Yep, there’s a Jay Leno episode where a guy installed a VFR800(?) engine in a baby Honda car (N360? something like that) and it was a weapon. Big Kawasaki’s are slowly becoming collectors items (a Z1 over here is a $20k bike now) but the later ones like the ZX series bikes are cheap, so a little Honda car with a big bike engine would be uber cool. Have you seen the Smart cars with Hayabusa engines? ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #411 on: September 28, 2020, 05:21:59 PM »
Terry,
I wonder how one of those engines would do in a small mini-car like the 70's Honda 600 or one of those tiny European automobiles ? I know they're air cooled so that would be a problem

I'd go for a VFR1000R for an S600 or 800 swap.  Kind of like a baby Lancia. ;D ;D

Sounds excellent,although it might need a special exhaust fabricator to make it work on any of these,but what a Blast !
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline RAFster122s

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #412 on: September 30, 2020, 11:56:46 AM »
A fellow did a mid-engine install of a very fast motorcycle into a Mini Cooper that I saw a month or two ago. It was very fast and quite unique as well. Very clean install.
David- back in the desert SW!

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #413 on: October 02, 2020, 04:42:25 AM »
Yep, one popular mod for mini guys is grafting a BMW K100 cylinder head onto a standard Mini block, apparently with the DOHC and BMW EFI, it doubles the standard Mini's BHP. Personally, if I had one, I'd install a modern FWD 4 cylinder engine and gearbox out of a Jap car like a Mazda or Honda, or even a Hyundai, more than enough power to turn a 1960's econobox with no power at all, into something that can stick with current econoboxes...... ;D

Today I had no particular intention of doing anything, but because the weather was so good (mid 70's, sunny and warm) after I'd done a hard days graft from my humble "home office",  I just had to go out to the sheltered workshop and do something. I made the mistake of test driving a bottle of my "Ginger Rocket" which just about sat me on my arse, and didn't set me up well for doing the valve clearances. Luckily I measured them yesterday when I was sober(ish) so I had written down what size increases were required for the shim swap.

Friday bike fettling 2 Oct 2020 3 by Terry Prendergast, on Flickr

Obviously the base circle of the Norris .425" cams was a fair bit smaller than that of the GPZ1100 cams, but I'd bought a set of new 13mm shims, so was pretty happy that I could get the clearances down to the .05-.10mm range as specified in the manual, leaning towards .10mm, for a bit more clearance, rather than not enough. Kawasaki specifies a clearance of between .05 mm and .10mm which is just between 2 and 4 thou (.002" and .004" in the ancient language of the druids) and most hot cams I've had over the years have specified around 5 thou, so I won't be too hurt if it's on the looser end of the two arcs of fire.

Because the GPZ1100 head has the much safer "Shim under bucket" valve adjustment setup, the downside is you have to remove your cams to change the shim. Here are some pics, which are fairly self explanatory. First of all, the "bucket":

Friday bike fettling 2 Oct 2020 4 by Terry Prendergast, on Flickr

The buckets are a very close fit inside the head casting, so the easiest (only) way to pull them out, is with a strong magnet:

Friday bike fettling 2 Oct 2020 6 by Terry Prendergast, on Flickr

The good thing about using a strong magnet is it also pulls the shim out of the special spring retainer:

Friday bike fettling 2 Oct 2020 7 by Terry Prendergast, on Flickr

Friday bike fettling 2 Oct 2020 8 by Terry Prendergast, on Flickr

So all I had to do was measure the shim that I pulled out, and find another shim between .2mm and .4mm thicker, and pop it back into the retainer:

Friday bike fettling 2 Oct 2020 9 by Terry Prendergast, on Flickr

And that was pretty much it. I thought I'd helicoiled all the stripped cam saddle hold down bolt holes that were suspect, but I found another one, so carefully helicoiled that sucker before re-installing the cams.

Friday bike fettling 2 Oct 2020 9b by Terry Prendergast, on Flickr

I re-installed the cams, re-did the timing, double checked it by cranking the engine over a couple of times, and packed up for the night. Unlike a CB750 engine, the big Kawasaki engine takes a fair bit of effort to turn over, and I was worried about it before I built the 900/1100 engine and it was the same, so I'm pretty confidant that it's ready to go back in, after I slightly clearance the cam cover just a tad more tomorrow, because I can see that it's sitting ever so slightly over to the left, and I don't want to be farting around with it once the engine's back in the frame.

As my fuel tank liner kit for my Effing F2 hasn't shown up yet, I may as well keep going with the 1428 this weekend, hell, I might even make some noise, not that I haven't said that a few times already, lets see what happens tomorrow......... ;D 







I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline RAFster122s

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #414 on: October 02, 2020, 04:56:25 AM »
Volvo 240s had shimmed buckets but the shim was on top if I recall correctly and there was a special tool to depress the bucket so you could slide the shim out with a magnet. They rarely needed any shim changes...even with 150K miles I never had to change the shims. Was amazing to me.
David- back in the desert SW!

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #415 on: October 02, 2020, 05:13:47 AM »
Volvo 240s had shimmed buckets but the shim was on top if I recall correctly and there was a special tool to depress the bucket so you could slide the shim out with a magnet. They rarely needed any shim changes...even with 150K miles I never had to change the shims. Was amazing to me.

Yeah mate, Z1-KZ1000's, Suzuki GS1000 (8 valve) and a few others  had "Shim over bucket" valve adjustment, but it's not ideal with hotrod engines with big cams, quite often the cam lobe will pick up the shim and flick it out of the bucket, and a hardened steel shim bouncing around your cam cover at a great rate of knots is not a good thing.

Kawasaki (I think) were first to use the "Shim under bucket" valve adjustment system, which every other manufacturer uses now, it's pretty much fool proof now. With milder cams (like in old Volvo's) the "shim over bucket" system would be fine, but not in these engines. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #416 on: October 02, 2020, 12:21:32 PM »
Volvo 240s had shimmed buckets but the shim was on top if I recall correctly and there was a special tool to depress the bucket so you could slide the shim out with a magnet. They rarely needed any shim changes...even with 150K miles I never had to change the shims. Was amazing to me.

My 1987' 240 is like that,very reliable even though the car is in the shape of a 'brick'..
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline RAFster122s

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #417 on: October 02, 2020, 01:51:32 PM »
Terry I found you another project bike. He says he cannot get spark.
David- back in the desert SW!

Offline RAFster122s

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #418 on: October 02, 2020, 01:52:31 PM »
I told him to put a chain around it attach it to his truck's bumper  and drag it down the street faster to get more spark from it...
« Last Edit: October 02, 2020, 02:28:34 PM by RAF122S »
David- back in the desert SW!

Offline spotty

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #419 on: October 02, 2020, 04:36:31 PM »
Terry I found you another project bike. He says he cannot get spark.

FT500 ? Or as you colonials call them , an Ascot ?
i blame Terry

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #420 on: October 02, 2020, 05:51:28 PM »
Volvo 240s had shimmed buckets but the shim was on top if I recall correctly and there was a special tool to depress the bucket so you could slide the shim out with a magnet. They rarely needed any shim changes...even with 150K miles I never had to change the shims. Was amazing to me.

My 1987' 240 is like that,very reliable even though the car is in the shape of a 'brick'..

My brother had one, and as ugly as it was, it went really well, and was fun to drive. It  reminded me of a Dudley Moore movie, "Crazy People" about an advertising exec who had some issues, came up with an ad campaign slogan, "Volvo's, they're boxy, but they're good". I always laugh when I think of that....... ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline PeWe

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #421 on: October 02, 2020, 10:02:33 PM »
Volvo 240s had shimmed buckets but the shim was on top if I recall correctly and there was a special tool to depress the bucket so you could slide the shim out with a magnet. They rarely needed any shim changes...even with 150K miles I never had to change the shims. Was amazing to me.

My 1987' 240 is like that,very reliable even though the car is in the shape of a 'brick'..
I had an 140, 1969 with B20 sand cast engine ;D
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Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #422 on: October 02, 2020, 10:32:36 PM »
I would love to find a P1800 sport wagon,a very nice vintage sporty Volvo.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline PeWe

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #423 on: October 02, 2020, 10:40:35 PM »
P1800 did not cost that much here in the early 80's. Often around $1500 US .
CB750 K6-76  970cc (Earlier 1005cc JMR Billet block on the shelf waiting for a comeback)
CB750 K2-75 Parts assembled to a stock K2

Updates of the CB750 K6 -1976
http://forums.sohc4.net/index.php/topic,180468.msg2092136.html#msg2092136
The billet block build thread
http://forums.sohc4.net/index.php/topic,49438.msg1863571.html#msg1863571
CB750 K2 -1975  build thread
http://forums.sohc4.net/index.php/topic,168243.msg1948381.html#msg1948381
K2 engine build thread. For a complete CB750 -75
http://forums.sohc4.net/index.php/topic,180088.msg2088008.html#msg2088008
Carb jetting, a long story Mikuni TMR32
http://forums.sohc4.net/index.php/topic,179479.msg2104967.html#msg2104967

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #424 on: October 02, 2020, 11:27:32 PM »
P1800 did not cost that much here in the early 80's. Often around $1500 US .

I think it's a nice car,I don't see any of them anymore.My father's parts counter employee had a factory purple wagon.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.