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TOPIC: 1984 KZP Restoration Kickoff

1984 KZP Restoration Kickoff 6 years 6 months ago #218353

Kickoff post for a ground-up repair and restoration on a 1984 KZ1000P ex-Atlanta PD patrol bike. An '06 quick-n-dirty reassembly of this former (near) basket-case was done with severe time and budget limitations. Some problems were fixed, some not. I've put a few miles on it since, but finally decided that some old problems (and several new ones) needed to be addressed. Disassembly is complete, and I'm trying to psych myself up to crack open the engine.

84KZP_SML-c8f9e27207ab93f91ec6693ad78582c3.jpg


I'm also currently struggling with the classic "powder or paint" decision. Powder coating would be cool, but I'm concerned about maintenance. Painting could be cheaper, and I'm really leaning toward Por15 products, which I've read good things on.

For the engine, low compression and a noisy transmission will need to be addressed. Maybe a few surprises here, as the bike was stored for 15 yrs.

A racing book I once read (maybe Carroll Smith?) advised "Make it safe. Make it reliable. Make it fast. Make it pretty. In that order.". Seems like good advice, so once it's back together and proven to be mechanically reliable I'll think about paint for the gas tank, fairing and fenders. Probably next year's project, but a deep law enforcement blue with white accents might look nice.

I won't really be able to enjoy riding it (especially on extended trips) until it can no longer be considered a work in progress. I'll try to post pics as progress is made.

Lastly, THANKS! in advance to all the kzrider.com regulars whose sage advice I'll need along the way.
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1984 KZP Restoration Kickoff 6 years 6 months ago #218388

  • RoyNor
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Welcome to the projects!

If you are looking for paint that really stick, looks good go for powder coat!
Just remember to put screws in the treads that you are using before you deliver it in for painting...otherwise you have to remove paint from it after, and thats no fun. :laugh:

I cant see any bad sides with powder coat, the 1000J I am restoring now was powdercoated for 15 years ago, and still looks fresh...

Good luck with the old police bike then! :P
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1984 KZP Restoration Kickoff 6 years 6 months ago #219133

Wheel Bearings
Bearings for both wheels came out fine (with a little BFH help). The trick was to go easy at first. Because the bearing/spacer clearance was so tight, the punch wasn't really able to get a good "grip" on the side of the bearing at first, but after a few taps the clearance between the bearing and the spacer loosened up very slightly. This allowed the spacer to be moved aside a bit more, which exposed even more bearing to aim for and strike harder. Once any grease seals and circlips has been removed it took maybe 10 minutes to knock the bearings out.

Front Rotors
Bad news here. Both rotors are below the min thickness. Just barely, but I was hoping to have them turned (If that can even be done on M/C rotors) to clean up some grooves left over from who knows what. At any rate, new rotors and pads are in order. I know where to get the pads cheap but the rotors are a different story. The only place I've checked so far wants $260+ for a new set. Too much. Looks like I'll be looking on ebay for a set.

Frame
Frame cleaned up nicely. At least it's straight with no cracks or other surprises. Now that it's clean I'll set it aside and attack the engine.

More later....
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1984 KZP Restoration Kickoff 6 years 6 months ago #219896

Front rotors: eBay came to the rescue. Shortly after posting about the out-of-spec rotors, I found a set on eBay from a '92 model. Luckily they were buy-it-now, and the seller reported that they were within spec. Bought them a couple days ago and they should be here early next week. I'll have my fingers crossed that they are as advertised.

Engine: Finally screwed my courage up and tore into the top end. What a mess. Severe carbon build up, and an overall "burnt" oil smell. While the circumstances surrounding the service retirement of this particular bike are a mystery, a theme of "Rode hard and put up wet" is starting to develop. I've not yet taken any measurements so I don't know just how deep the problems go. At any rate, a thorough cleaning is in order. Crossed fingers now doing double duty against severe engine wear!

Pics forthcoming.....
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1984 KZP Restoration Kickoff 6 years 6 months ago #219900

Time to try posting multiple pics. Apologies in advance if I screw this up....

Head condition for cylinders 1 & 2.


Cylinders 1 & 2.


Head condition for cylinders 3 & 4.


Cylinders 3 & 4.
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1984 KZP Restoration Kickoff 6 years 6 months ago #219912

  • Makarth
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i've seen worse, i would just make a cocktail of gas/seafoam and dip a nylon detailing brush in the solution and go to town with the parts. You could use a brass brush as well but it can still scratch aluminum. But hey i'll be back in the murfreesboro area mid july so if you need help just gimme a pm.

1977 kz1000 - Megasquirt project @ 40% wiring, plenum, and exhaust<--(done!)
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1984 KZP Restoration Kickoff 6 years 6 months ago #219972

Thanks, and I will.

That cocktail sounds potent! I'll give it a try. Got plenty of both on hand.
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1984 KZP Restoration Kickoff 6 years 5 months ago #221549

Spent the last couple days tearing down the engine to the point the crankcase could be split. Everything looks fine so far, considering the bike's history. Still no measurements made yet, so bad news could be coming. The case had been split sometime in the past, and the PO had made a mess with the liquid gasket used. The stuff is everywhere.
Split the cases last night, and lifted the crank and gear shafts out. There are some wear patterns in the cases where the gear shafts (bearings) sit that concern me. Slight grooves and friction points in the aluminum that I'll need to have looked at. Probably have my friendly local dealer check it out (Rose Kawasaki).
New bearings are in order, at least, while I'm in this far.
Pics:




This next week I'll have a chance to thoroughly check the crank and gear shafts for excessive wear or other problems. Hopefully the bearings won't give me any trouble.

More later......
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1984 KZP Restoration Kickoff 6 years 5 months ago #223057

Crankshaft and transmission shafts seem to be fine. Crankshaft bearing clearances are within spec, and there doesn't seem to be any play in the rod or main bearings.

I've disassembled the input and output shafts and found both large main bearings to be questionable. Hopefully I've found the source of the transmission noise that started this whole project. Both vibrate and make noise when spun by hand. I'll be taking these to the local bearing shop for replacement. All of the smaller needle bearings seemed fine, but at less than $8 each I'll almost certainly replace them as a precaution. New circlips, too, while I'm at it (per the book).

Once I have the transmission bearings in hand, I could go ahead and reassemble the crankcase. Instead I'll probably wait until the cylinders are ready to go back on so the lower engine will be sealed, and the errant doo-dad can't get lost under the crank.

Funds have run low for the moment, so I'll probably concentrate on de-greasing and cleaning the million small parts I've taken off.
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1984 KZP Restoration Kickoff 6 years 3 months ago #237289

Haven't updated in a while, though much progress has been made and many problems solved. Nothing really to report until recently.

Frame: Powder coating was completed a couple weeks ago by Jason Greene of Greene Finishing (706-517-0757). What a fantastic job! The pics really don't do it justice. The easiest way to describe the result is simply "It looks new!". If you're anywhere in the N GA or East TN area, I highly recommend Jason's work. Very experienced, and easy to work with.


More updates below.....
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1984 KZP Restoration Kickoff 6 years 3 months ago #237290

Engine is almost done. Most of the problems here had to do with part sourcing, especially bearings. Easy enough to order OEM if you want to pay through the nose, a bit harder if you're looking for a bargain. In fact, if I hadn't lost track of a couple guide pins and o-rings it would be done by now. Hope to have the head on, cams in and back in the frame by Friday.
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1984 KZP Restoration Kickoff 6 years 3 months ago #237293

Wheels were finished last weekend. Considered powder coating, but decided to wait until I can find a set of wheels in better shape and I'm ready to replace the tires on the bike now. In the meantime a little polish and paint will have to do.


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1984 KZP Restoration Kickoff 6 years 3 months ago #237296

Forks were tonights project. They were in pretty bad shape, so a complete strip and polish was needed. Knocked the old varnish off with some spray gasket remover, which is basically spray paint stripper (bad stuff, too, so don't get any on you). Followed that with some scotchbrite pads, some white polishing compound, and finally some Mothers aluminum polish on a Powerball.



Those Powerball's are pricey, but worth the money. I picked up the small one, and it does a good job of getting into the nooks and crannys.
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1984 KZP Restoration Kickoff 6 years 3 months ago #237301

  • PLUMMEN
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looking good B) id like to find an old police bike to build bike to get lost between states on the weekends,i want an 80 or older though since ive got tons of engine parts for the older stuff ;)
Still recovering
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1984 KZP Restoration Kickoff 6 years 3 months ago #237326

  • Tony
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Nice work LeeLewis7! Very inspiring. What did you do for a finish on your engine? It looks very nice.
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1984 KZP Restoration Kickoff 6 years 3 months ago #237687

Engine is done except for double checking the valve clearances. Finished it a few nights ago. Setting the cam timing was easier than expected. Using the marks on the cam sprockets and the repair manual make it (almost) a foolproof operation.

The valve cover wasn't taking a shine like I'd hoped, so I opted for quick and easy. Polished the ends, then rattle can-ed the rest with some Dupli-color "Steel" wheel paint. Practically an exact match on the color, but I'm worried about how it will hold up. A few drops of gas and it'll probably look like junk. Easy enough though to pull it off and send it to the powder coater if the paint becomes a problem.
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1984 KZP Restoration Kickoff 6 years 3 months ago #237692

Tonights project was getting the engine back in the frame, and then working toward completing the "rolling chassis".

As you can see, the engine is in but I didn't get much farther than that. If you're ever looking for a way to advance your cursing skills, I highly suggest trying to wrestle a bike frame down over an engine by yourself. I feel like I should go to confession, and I'm not even Catholic. Installing a block without a piston ring compressor works pretty well, too. Either way, you'll be using your entire four-letter vocabulary, and probably inventing some new ones.
I was at least able to get the triple clamp, forks and front wheel on. I'm happy with the results, and thrilled that it starting to look (sort of) like a motorcycle again.
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1984 KZP Restoration Kickoff 6 years 3 months ago #237744

  • Old Man Rock
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And I thought my engine was coming out clean... holly crap that looks sweet!

What looks better, your engine or Halle Berry in a see through? hmmm..... OMR ponders :laugh:

Keep the images coming.... damn that makes me want to rip the engine out again...

OMR
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az
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1984 KZP Restoration Kickoff 6 years 3 months ago #237855

  • Shoe48
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I really liked my cop bike alot ,, Yours is looking great .. WoW
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1984 KZP Restoration Kickoff 6 years 3 months ago #237876

  • The Gringo
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Old Man Rock wrote:
What looks better, your engine or Halle Berry in a see through? hmmm..... OMR ponders :laugh:

The engine looks nice but I'll go for Halle everytime. That's one woman I never get tired of looking at.
Andy
Akron, Ohio
80 Z-1 Classic-Sold
84 GPZ1100
79 KZ 1000 LTD
78 KZ 1000 A2
77 KZ 1000 LTD-Sold
76 KZ 900 The definition of a barn find
76 KZ 900-Sold gone to Denmark
KZ 750 times 3, KZ 650 times 8 Sold 1 down to 7
KZ 550 times 2 80 440LTD-Sold
81 CSR 305-Sold 81 Yamaha XS650 Special
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