Kawi2strokes.com Forum

Ill give it a try, maybe my biggest problem is Im trying to hard to be perfect
What is the worst that can happen….. they make more pistons every day! I've wrecked more expensive stuff in my life

Im really not much of a mechanic , like Ive said before I can follow directions reasonably well and Im not a complete fumble fingers But WOW, i didn't realize how much easier it was going to be putting pistons in with separate cylinders as opposed to an in line four.
Didn't take long at all, and then no cams, no cam timing, no checking valve clearances, I suppose the hard part will be in the timing and tuning.
I put the heads on just to keep it sealed up.
My question is how many of you weld the H2 heads to keep them from cracking?
It seems from what I've read I should have it done, just looking for opinions if anyone has one


The lift helps too, best thing I bought in a long time.

Actually it is kinda rare, usually with very hard use.

The bike is looking great!

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

Just thinking aloud, I wonder if it's a function of over-tightening heads....? (Not that I've had a H2 engine anywhere near 9,000 revs.)

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"One day, your life will flash before your eyes. Make sure it's worth watching." : anon.

I have read here that torquing to 24 ft lbs helps.
I will do that, then I can button it up and do a pressure/vacuum test. And if the heads crack I'll send them to you Moo and do something expensive
Im getting excited to try to work out all the gremlins once its road worthy!

looks like your on the home stretch

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she will never be pretty but she is a fun ride.

73 KAWASAKI H1 (Sold).
82 YAMAHA RD350LC
2000 KAWI KDX200H
2001 Triumph TT600

Im sure there are going to be a few more hurdles to overcome. This is the biggest bike project Ive ever done and it has really stretched my ability. Its a whole new learning experience
Ive only done two engine rebuilds before this and some simple reworking of existing systems.
Here are a few more pics of the lights working. Used a LED for the headlight low beam and a 35 watt H4 scooter bulb for the high beam. I just cut the back of the stock headlight and epoxied a H4 holder cut from another head light in place. and drilled a small hole for the LED and used an old instrument socket from spare parts. I don't plan on driving at night much so the H4 bulb is really just in case, the led is a tiny on, it glows the head lamp but casts no light. The brake light is LED also. The blinkers were .86 cents apiece I don't think they will last long but at that price I had to see what you get, they look good standing still and maybe they will last a season. They are 8 watts, and I found a blinker relay in all the boxes I had from my cousin and it works fine. I am also wiring the shift light from the Zeel to the red brake light in the tach. The tach I also found cheap have to wait to see if works, it spins with my drill
Im wiring the kill switch as the main power and will do something to disable the ignition when I park it somewhere.

Easy to see that you are on the right track, and it will come together nicely - neat and methodical approach!

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"One day, your life will flash before your eyes. Make sure it's worth watching." : anon.

Do you have a rubber mounted engine?

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I am just a man working in a tin shed.

No, I thought about it a lot, I didn't think I had the skills to pull it off with the cases I have, and I didn't have the $$ for new cases.
I did shim it, I think I did a good job, took some time, I ordered a bunch of specific size shims from McMaster car and got the fit to what the resource site suggests.
WHY?? Ive heard the horror stories about vibration and cracked frames.