Sugi'sRestoration Page

"Low-Tech" Sugisaku's "DOUJOU" of Forced Restoration

Victim Number 2 : KAWASAKI H2 750

The conditions of "Before"

The photo shown below is my H2 KAWASAKI before the restoration work. I felt the restoration is easy because the overall condition was not too bad. Unfortunately, the clocks and the indicators were missing but it kept the original paint (although it has scratches and rust ) and it had no rust inside of the fuel tank. Honestly said, I never seen the actual bike when I decided to purchase the project bike (when I made the decision, the bike was on the sea). However.......

H2before H2before2

When I saw the photo took from the back side, I believe firmly that the rear wheel is "leaned"! I thought it may be leaned because it stored for years with the side stand. But the tire was ware away a lot at the left side compared to the right side so the previous owner should ride with "leaned" rear wheel for long time! What should I do for it?

The front brake was completely dead. The brake oil reservoir was full of "Slime" which was brake fluid previously. I was surprised that a brake fluid is turn to this kind of state.

I looked for the used clocks, ignition switch and indicators through Internet and I could get the items, successfully (thank you very much Todd and Ron). The ignition switch didn't have the key so I asked to a locksmith near my house to make a key for the switch.

Repair of Engine (Carburetor)

After I received the key and I installed the clocks, I tackled to fire the engine at first. I started from rebuilt of the carburetors. As same as HX90, throttle sliders hardly stacked into the body so I could remove the sliders with penetrating oil and open the throttle top cap with power as I did for HX90. I cleaned up messy float bowls and jets then I set the cleaned carbs to the engine. I installed a new battery because it didn't have a battery. When I turned the key, neutral indicator was turned on. It was good sign. (When I did the carbs clean up, I didn't have a spare time to take the photos)

Repair of Engine (Start up the Engine!)

I installed new plugs and I checked the ignition systems are dead or alive. I could see weak sparks when I kicked the engine. I was lucky because the CDI system was still alive. I pour oil into the oil tank (it was empty!), and pour pre-mixed fuel for safety. I pushed down the choke lever and kick the starter for several times. Wow, the engine was started without any difficulty with very noisy sound. Kawasaki motorcycle is great (?). I thought the engine noise was too noisy but I thought it may be okay. The picture shown below is the picture of memorial engine fire up. You can see the white smoke out from the exhausts, can't you?

Engine Fire Up!

Repair of Engine (Clutch repair)

The engine was running so is there someone who can stand to ride it? I grabbed the clutch lever, shift up to the first gear (the gear change pattern of H2 is all up! )... engine stopped. What? Try again! I shifted down to the neutral, start the engine and.... engine stopped. Oh dear, the clutch plates may be stuck! It remind me the experience of HX90, so I try to remove the stuck clutch plate with "Power" (that's why this is forced restoration!). First, standing the bike with center stand. Tow, ride on the bike and start the engine, then grab the clutch lever and shift the gear. The clutch plates were stuck so the rear wheel was turning freely. Open the throttle to increase the rear wheel turning speed then sit down to the rear seat to touch the rear wheel to the ground.

Kyu Kyu Kyu ..........engine stopped. (with white smoke and smell of burned rubber)

It didn't work. I've got success in case of HX90.

As the final option, I tried to the method that while engine turned high revs in neutral, grab the clutch lever and shift up the gear suddenly! (this is highly possible to broke the gears when I considered this. Primitive shock treatment?)

Guaan Guaan (engine noise)... Tick! (sound of shift up)

Kyu Kyu (bike go to forward! I was surprised!).... engine stop.

Oh, this was very scary! (at this point, the front brake did not work so I thought that if the bike go to forward quickly, I should use the rear brake. However, it was very hard that I shift up the gear with left foot and brake with the right foot as soon as I did the gear shift up, wasn't it?)

Okay, I'll try once again!

Guaan Guaan (engine noise)... Tick! (sound of shift up)

Boom.. Guaan Guaan (engine noise)

Yeah, the plates are coming off!! I've got it! (It was safer to open the clutch case cover and remove the plates than this forced method)

Any way, "All's well that end's well"!


What a silly! And then?

Is this restoration? No way! I'll go back to the home!