Kawi2strokes.com Forum

Hey now! Actually, I got stuck as my boring guy doesn't have a hone small enough to do the cylinders, and too some wind out of the project. And now with the 500 blown up, I have more to do......

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Twist the throttle, tilt the horizon, and have a great time. What triples are all about...........

very nice, just seen this thread, though prob too late now a late Z650 disc is thinner lighter and drilled from the factory, it bolts straight onto an S Series hub


Gary T

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Wine for my men we ride at dawn

hi Gary.. If you look closely, the disc in my pic IS indeed a Z650 (actually KH500, but same thing ) that has been both drilled AND thinned to 5.5mm.

That said, as we speak, I have another KH500 disc being cut down to match the pad-contact surface of a 2008+ Ninja 250 Caliper..
Basically Moo's EX500 Caliper and Disc Cutout, but with a more modern caliper and the lighter 4 hole rotor.

Some nice black wheels got there.

Have you decided on a front fender yet?
I used a 1981 Kawasaki CSR KZ305-A1 fender on my H1. It's just a tad wider than my 110/80-18 front tire.

PK


.

I did, and its pretty bare bones. I forgot what exactly its off of. Yamaha something-or-other.

That's a great pic BTW!

I know Cody will come up with a really awesome bike,but I have to say one more time PK your H1 is such a cool bike !!!!!

THE SEAT....

This has been a VERY long chapter in this bikes' build. I guess I'll let the cat out of the bag in that I am FINALLY going to be using Aylors Fiberglass Early H1 tank.
I bought it from John about 5 years ago, sold it to a friend, and then bought it back again about 2 or 3 years ago.

Tank itself was fairly easy to fit. I just cut the stock S3 rubber puck-mounts off the frame and rewelded them to to the horizontal tubes.


These now sit in the indentations John molded into the tank. The front of the tank is held in place by a single 6mm acorn nut, and the rear of the tank is held (locked) in place by the seat..... It turned out really well.


Since Im using the early H1 style tank, I felt it had to have an early H1 style seat....or at least a nice tribute.

I started with one of my rusty early H1 seat pans/foams just to see what it might look like.. Hmmm? Chop 4" out of the front of the pan, weld on S3 hinges (so I can access oil tank/electrics/ect)
That might work.




Used part of a phillips screwdriver (from a Honda CL350 Tool Kit.. ) to make the "catch" that the stock early H1 seat latch holds on to.


Once I could picture it in the minds' eye, I went ahead and made some paper templates to follow the contour of the S3's frame.


I then ran up to my buddy's shop and used his plasma cutter to make the extensions out of steel, tigged them to the pan and then cut away the old rusty crap. I didn't think to take any photos of the finished pan, but it turned out excellent. In the front of the pan is a molded "cup" that holds down a rubber bumper fixed to the rear of the Gas tank. It keeps it centered and very well secured.

Next, I ordered a new reproduction foam and proceeded to chop about 4" out of the front...


I didn't like it....

So after some strategic glueing and grinding, I came up with "this"... Kinda sorta a Giuliari/Early H1 Hybrid...


Tools of the trade (not shown is 3M spray adhesive)



One of the things I knew had to happen was the tail light had to be an intergral part of the seat. THIS turns out was the most difficult and time consuming part. This seat has been re-upholstered 4 times now.... Seriously.

I'm finally happy with it.

Version 1.0 (Original Foam with Buell X1 Lightning Tail)


Version 2.0 (KH750-esqe tail light in unmodified new early H1 foam) **You can see in this pic the newly welded side/rear pan extensions**


then the search began... Knowing this bike was going to be mostly "Blacked-Out", I started looking online for a Black LED tail light. After a bunch of photoshop cut-n-paste, I found what I think is a really cool light. It is repop for a Honda CBR1000XX Blackbird. I wanted it to look like it was growing out of the seat...



Im happy with that!

And the coolest thing about this light is that it has Intergral Turn signals...and uses little to no power since it is L.E.D.

Running Light


Brake Light


Right Turn


Left Turn


And off once again....


and a couple of side views..



I wasn't planning on using Gold '69 Piping, but since the Ti-Ni'd front fork tubes... well, uh... it needed some more Gold. And no, the bike isn't going to be painted midnite white. Final touch was "modifying" some stock stainless trims (sorry to the purists )
I just used a hacksaw to cut to length, bent them by hand and a vise (to take the "Z" shape out of them) and re-hammered the cut end into a tapered-round shape like original using the ball peen hammer my dad made in 8th grade and a piece of rail road track....



So thats pretty much it!!!! I still haven't decided if I'm going to stencil KAWASAKI on the back???





Now I've got to get back to workin on those fork ears...

Well done . That looks seamless and professional. Long tank, short seat..racy.

That is really turning out nice Cody!

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Twist the throttle, tilt the horizon, and have a great time. What triples are all about...........

very good job on the seat, i might get you to make one for me as RB broke mine this morning. Only joking just a coulple of screws fell out.

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If Satan had a bike and fed it cats it would sound just like my bike.