Topic: Terry's Kawasaki Mach III 500 build. Let the smoke begin.....

[Stev-o]

I had a girlfriend in early 80's...

Pic or you didnt do her!

[Terry in Australia]

I think that with modern synthetic oils the smoke would be minimal, but 2 stroke engines are thirsty, so even with modern injection technology etc, they probably aren’t viable in cars. Motorcycle riders aren’t as fussy about gas prices as the majority of bikers really only use them for leisure anyway, so I think a modern 2 stroke bike would still sell reasonably well.

Not a dirt bike for me but a 750 triple or 1000cc four, would be a great bike, light, nimble, with a comfortable riding position and good brakes and handling is what I’d want.

[PeWe]

I had a girlfriend in early 80's...

Pic or you didnt do her!

Ha-ha-ha!
Sorry, no photos. I did not carry a camera back then. Early 1982. She lived in another town.
Brown hair, tall with very long legs and wearing high heals. A painful screaming back scratcher with long nails all night long ...... But psycho problems..

[Terry in Australia]

I know that feeling Per, I’ve got scratches all over me from last night’s session, I really must trim my nails….

[PeWe]

[Tintop]

At one point the family had a DKW 2 stroke, you had to mix the oil & gas.  It got traded for aa Volkswagen.  Much slower than the DKW.

[Terry in Australia]

I remember seeing a few of the 2 stroke Suzuki mini 4WD’s getting around in the 70’s, I wouldn’t mind one of them now. I’ve seen one or two pop up on FB Marketplace but the rust weevil’s must have had a taste for Japanese back then, because they hadn’t fared well. I did some rust repairs on an early 4 stroke Suzuki 4WD and it was a horrible mess of rotted out internal panels that obviously weren’t designed to withstand immersion in muddy creeks etc.

I was watching a Youtube video of Kaplan wandering through a motorcycle graveyard of around 3000 bikes that had been left to rot yesterday, and almost cried, lots of CB750’s, and many Kawasaki, Suzuki and Yamaha 2 strokes, well beyond restoration. I’m glad that mine won’t be going to the scrap metal plant.

[Terry in Australia]

Anyhoo, yesterday I drove over to Hussein's place to pick up my vapor blasted engine. He did a magnificent job, he even removed all of the small pieces of hardware that I hadn't, and individually blasted them as well.

Mach 3 meandering Sunday 2 April 2023 by Terry Prendergast, on Flickr

The best part is that it cost me nothing. Hussein is restoring an ancient Honda twin (1958, apparently) and while he's blasted and painted the frame etc, he wasn't confidant enough to strip his engine, so the deal is that he'll do all my Kawasaki parts (including the carbs and outer cases that I haven't given him yet) if I disassemble his little engine and take the cases, cylinder block, head etc over to him to blast, then put it back together so he can shove it into his frame. It's a cute little engine.

Mach 3 meandering Sunday 2 April 2023 1 by Terry Prendergast, on Flickr

I need to clean my workbench in preparation for pulling the little honda apart, reassembling the Kawasaki's engine, and building a K6 engine for Dion, in exchange for a 1973 Mach III paint set, and all of his leftover Kawasaki 500 parts. I'll do that later, I'm going into hospital tomorrow for some minor back surgery, and won't be doing anything too strenuous for the next week or so, so today I'm going for a ride. It's not real warm, but nice and sunny, so good enough.

[grcamna2]

Terry,The Kawasaki H1 engine looks just marvelous after that shining vapor blasting job.
I'm interested in learning about that little twin;is that from a 150 Honda Dream model?

[Terry in Australia]

Terry,The Kawasaki H1 engine looks just marvelous after that shining vapor blasting job.
I'm interested in learning about that little twin;is that from a 150 Honda Dream model?

I reckon you're right Bill, I had a 150 Dream (or whatever they were called) back in the 70's, I bought it for 5 bucks and never quite got it going. Hussein also has a VFR800 in his garage that needs some work, I think he'd like me to buy it.......

[RAFster122s]

Benly Touring 150, often referred to as a Baby Dream because of it similar looks to the Dream CA77/CA78 bikes. CA95 is single overhead cam single carb twin with lost spark points ignition with points driven off camshaft. Two valve per cylinder and chain drive cam.
The CB95 was a race bike primarily and few were made and sold to public, think CB160 with 154cc instead of the 125cc of the CB160/CA92.
Like a CB160 it had proper front tubular fluid filled hydraulic shock absorption and chrome fenders front and rear but a backbone frame of the CA95. The CB160 had a proper tubular frame, not the pressed steel backbone design used on the CA bikes.
50-55 mph was typical top speed of the CA95...the suspension was a leading axle design where the front would raise up during braking, just like that of the C70 Passport bikes. Really a spring and lever type front suspension, not designed for higher speeds but it wasn't a high speed bike. Drum brakes front and rear.

[BenelliSEI]

Terry,The Kawasaki H1 engine looks just marvelous after that shining vapor blasting job.
I'm interested in learning about that little twin;is that from a 150 Honda Dream model?

I reckon you're right Bill, I had a 150 Dream (or whatever they were called) back in the 70's, I bought it for 5 bucks and never quite got it going. Hussein also has a VFR800 in his garage that needs some work, I think he'd like me to buy it.......

Those cases and bits lot great. The stuff I had done a few weeks ago, was my first vapour blasting. I’m hooked too!

[Terry in Australia]

Terry,The Kawasaki H1 engine looks just marvelous after that shining vapor blasting job.
I'm interested in learning about that little twin;is that from a 150 Honda Dream model?

I reckon you're right Bill, I had a 150 Dream (or whatever they were called) back in the 70's, I bought it for 5 bucks and never quite got it going. Hussein also has a VFR800 in his garage that needs some work, I think he'd like me to buy it.......

Those cases and bits lot great. The stuff I had done a few weeks ago, was my first vapour blasting. I’m hooked too!

Thanks John, and thank God that most of my other Kawasaki cases and hubs etc are already vapor blasted, over here it's horribly expensive, the K0 cases, cylinder block and head etc cost well over $1000 AUD several years ago and even the T500 cases were close to a grand. If I was to keep restoring bikes, it'd probably be more economical for me to buy my own blasting set up. Hmmnn, I do like tools.....

[RAFster122s]

If ya buy the setup Terry, once you are dialed in and have got good results then you start picking up some side jobs for others to pay for the machine and give you some retirement coin to enjoy for whatever you need or just to bank.
You talked about getting a different place for part of the year, a good setup and develop the rep and you will have a steady stream of income without taking all your time.

[MauiK3]

It all looks great.
I'm shocked at what vapor blasting costs. I'm going to urge my contact on Oahu to get set up, I'm sure he'd be swamped.

[Stev-o]

Terry,The Kawasaki H1 engine looks just marvelous after that shining vapor blasting job.
I'm interested in learning about that little twin;is that from a 150 Honda Dream model?

I reckon you're right Bill, I had a 150 Dream (or whatever they were called) back in the 70's, I bought it for 5 bucks and never quite got it going. Hussein also has a VFR800 in his garage that needs some work, I think he'd like me to buy it.......

Those cases and bits lot great. The stuff I had done a few weeks ago, was my first vapour blasting. I’m hooked too!

... over here it's horribly expensive, the K0 cases, cylinder block and head etc cost well over $1000 AUD

IIRC, I paid $350 to get my H2's case, cylinders and heads vapor'd by Nil's in AZ.
But that was about 4 yrs ago when he was just starting out and he cut me a deal.
I've found a guy in Austin that does it, but I haven't contacted him yet, it does seem to be gaining popularity. 
Forum member "B ridin" did some aluminum automotive valve covers for me recently for $60 + shipping to Dallas, thought that was reasonable and they came out looking great.

[Terry in Australia]

Thanks guys, yep, vapor blasting, sandblasting/powdercoating and painting (not to mention chroming) are horribly expensive here. I guess with a small population and a lot less competition, these specialists can charge what they like. Luckily the vapor blasting was "free" just requiring my labour to strip and reassemble Hussein's C92 engine so he can blast it, and building an 836cc engine for Dion, who's painting my '73 tins, and giving me the rest of his H1 Hoard in exchange.

Sadly I don't have a "deal" like those for the frame, so I'll need to pony up the dough. I rang the powdercoaters yesterday, it seems that Michael, the boss, didn't get the message that I'd decided to get the frame powdercoated last week, so my bare, blasted frame has been sitting in their warehouse waiting for me to collect it. I rang yesterday to see if it was ready to collect, and found out that it wasn't powdercoated, so Michael apologised profusely and promised he'd call me in a couple of days when it's done. No biggie, but I would like to get a rolling chassis happening ASAP.

The mailman just delivered a set of "Allballs" steering head bearings, so I better get the forks rebuilt, paint the triples, and find all the other bits to get a rolling frame happening. It will be nice to have a roller to look at while I reassemble the engine.

[Alan F.]

How's the back doing Terry?

[Terry in Australia]

How's the back doing Terry?

G'Day Alan, pretty good thanks mate, was pretty sore on Monday after the surgery so I took lots of painkillers, yesterday was much better, and today, funnily, it's a little sorer than yesterday. No biggie though, I was expecting it to be really sore for a few days, so I'm pleasantly surprised. Definitely going for a ride on the weekend!  

[Alan F.]

We'll keep a good thought for you.

[Kelly E]

I've found that a serious project that requires a lot of head scratching really helps me to completely forget about my pain to the point where I forget to take pain meds.
Like building an exhaust system for the 78' KL 250 since the only place that makes one is months behind and not taking orders. I'm using the stock head pipe, parts of the number 2 and 3 head pipes from the old 82' CB 900F exhaust system and the original right side muffler from the 84' Sabre 700. I need to finish up the last weld and make mounting brackets. It's all double wall pipe so at each cut I tack weld the inner tube to the outer tube before welding the sections together so it doesn't rattle. I have no idea if it will work or how long it will last but hopefully until I can get a proper exhaust system for it.

[Terry in Australia]

That looks great Kelly, and I'm in awe of you working so fast with your own medical issues, well done mate. Do you have a TIG? I've just bought one (well, for Christmas, but it hasn't fired a shot yet, I need an exhaust project to give it a run) and am keen to try it out.

The wife took a pic of my back so I could see what the surgeon did, I was expecting two holes, so I'm not sure if he missed a couple of times, or if he had to shove a scope in there to direct the RF burner? Either way, big scars would have been cooler, but at least I don't have to worry about tearing stitches.

Mach III hoarding 5 April 2023 6 by Terry Prendergast, on Flickr

I was bored out of my brain yesterday, so today, after the wife went over to look after her 91 year old mother, I sneaked out for a cigarette, and whilst staring at Hussein's C92 engine, I went into some sort of trance, and when I awoke, suddenly it looked like this.

Mach III hoarding 5 April 2023 by Terry Prendergast, on Flickr

I've harvested these parts for him to start blasting, but I need his workshop manual before I split the cases, as this little engine is totally alien to anything I've ever pulled apart before, and I can't afford to break anything, as I'm guessing these little buggers are pretty few and far between.

Mach III hoarding 5 April 2023 1 by Terry Prendergast, on Flickr

What's all this got to do with my Mach III? Well this was the tradeoff for free vapor blasting for my parts. I sent Hussein a message with these pics and arranged to take them to his place on Friday, and he told me to bring the rest of my Mach III parts (carbs, engine covers etc) over at the same time and he'll blast them for free as well. Bonus!

While I was slaving over that little engine, Dion sent me a text to say he needed more CB750 parts to build his second bike, and would give me the rest of his Mach III parts for building an 836cc engine for him, and he'd also paint my KZ1000 tins (actually Z1 tank and bodywork) in the "Jaffa" (brown/orange) scheme, as well as painting my '73 Mach III tins.

He sent me these pics, and said he also has the frames for another 1970, 72 and 73 H1.

Mach III hoarding 5 April 2023 5 by Terry Prendergast, on Flickr

Mach III hoarding 5 April 2023 4 by Terry Prendergast, on Flickr

Mach III hoarding 5 April 2023 3 by Terry Prendergast, on Flickr

Mach III hoarding 5 April 2023 2 by Terry Prendergast, on Flickr

I've got no idea where I'm gonna store all this stuff or even what I'll do with it all, but hell, it's nice to have a few spares.....

[spotty]

if it's all in tubs, which most of it appears to be, it can take up some floor space in my garage for a while, tanks can hang on the wall

[Terry in Australia]

if it's all in tubs, which most of it appears to be, it can take up some floor space in my garage for a while, tanks can hang on the wall

Thanks mate!

[ekpent]

That's a lot of horse tradin' going on there !