TOPIC:

good call on the safety glasses.glad it was no worse.

leon

Better?



A small portion of the metal I've removed from the head. If nothing else, the top end will weigh less!





Started porting and broke the cable on my Dremel!



Easy fix, just cut the extra sheath. Five minutes later, I was back in business.







The tangs on these shorty files were digging a hole in my hand, so I spent a little time on the belt sander.























Gotta run to town, get more supplies...

It looks like a lot of effort, I commend you for your work. I worry about your hand porting. Looking at your pics each port is a different shape. I think you might struggle with carb tuning. It's already bad enough with 4 carbs.

Haha, really?

Don't worry about my hand porting, I've had pretty good luck with it so far.

Anyway, those pics are like a week old, it's an ongoing process. I've been working nearly every day on this head for the last few weeks. Files, sandpaper, Dremel, blisters on me fingers and aching wrists. What I've mostly made is aluminum dust.

I like the little Dremel scotchbrite wheels, those are fun but they don't last long. My favorite tool here lately is my riffler rat tail file. Really good for the curvy little valleys on either side of the valve stem.



When I finally get the ports like I want them, and get all the casting flash knocked out, it'll go back into the soda box for a few days, then I'll ship it and a few other pieces off to my buddy's for vapor blasting. When it comes back, I'll look at surfacing and honing and what not.

Metal work proceeds at it's usual plodding, glacial pace. Soda blasting is on hold due to cold weather, any moisture in the air line freezes and constricts flow. I drain the air tank, the dryer at the compressor and the other dryer at the blasting cabinet, but it still freezes up.

Santy Claus brought me a clutch push rod, specifically for the KZ1000P.



On the left is a rod from a KZ1100.
In the center is The Mysterious Rod that came with the bike.
On the right is the new rod, which is entirely of steel.

Here's the end of The Mysterious Rod...



Somebody stuck a threaded bit on the end with JB Weld. My brother doesn't recall the origin story of The Mysterious Rod, but knows that he didn't add that bit on the end, it's been seven or eight years since he took this bike apart, and he doesn't remember if The Mysterious Rod even came out of this engine.

I find interesting the variety of lengths in these push rods. I'd have thought that the KZ1100 rod would be the same as the KZ1000P...

Damn, it looks like I might've gotten the wrong part...

This one is a 13116-1148, the parts diagram at buykawasaki.com indicates 13116-1033. The eBay listing specified 1991 model, I guess Kawasaki changed the design between 1987 and 1991.

Oh well, I'm out a whopping $16... or I could just cut this one shorter, chamfer the end and call it good! The question is... how long does it need to be? At present, it's about 13"...

Not sure they can be cut down as I believe the ends are hardened

bluezbike wrote: Not sure they can be cut down as I believe the ends are hardened

I do have an acetylene torch... though I'd rather just get the right part.

guitargeek wrote: Damn, it looks like I might've gotten the wrong part... This one is a 13116-1148, the parts diagram at buykawasaki.com indicates 13116-1033. The eBay listing specified 1991 model, I guess Kawasaki changed the design between 1987 and 1991....

Based on my interpretation of the info provided at kawasaki.com ---
Am thinking clutch push rod 13116-1033 as used in the earlier models was upgraded (somehow improved) on later models, at which time it was assigned another part number 13116-1148, whereby 13116-1148 became a "supercession" which also fits and may be used in the earlier models.


13116-1033
Model (18):
KZ1000-J1 (1981)
KZ1000-J2 (1982)
KZ1000-J3 (1983)
KZ1000-K1 (LTD) (1981)
KZ1000-K2 (LTD) (1982)
KZ1000-M1 (CSR) (1981)
KZ1000-M2 (CSR) (1982)
KZ1000-P1 (Police 1000) (1982)
KZ1000-P2 (Police 1000) (1983)
KZ1000-P3 (Police 1000) (1984)
KZ1000-P4 (Police 1000) (1985)
KZ1000-P5 (Police 1000) (1986)
KZ1000-P6 (Police 1000) (1987)
KZ1000-P7 (Police 1000) (1988)
KZ1000-P8 (Police 1000) (1989)
KZ1000-P9 (Police 1000) (1990)
KZ1100-B1 (GPz) (1981)
KZ1100-B2 (GPz) (1982)


13116-1148
Model (14):
KZ1000-P10 (Police 1000) (1991)
KZ1000-P11 (Police 1000) (1992)
KZ1000-P12 (Police 1000) (1993)
KZ1000-P13 (Police 1000) (1994)
KZ1000-P14 (Police 1000) (1995)
KZ1000-P15 (Police 1000) (1996)
KZ1000-P16 (Police 1000) (1997)
KZ1000-P17 (Police 1000) (1998)
KZ1000-P18 (Police 1000) (1999)
KZ1000-P19 (Police 1000) (2000)
KZ1000-P20 (Police 1000) (2001)
KZ1000-P21 (Police 1000) (2002)
KZ1000-P22 (Police 1000) (2003)
KZ1000-P24 (Police 1000) (2005)

Perhaps Kawasaki used a different hardening process incident to the supercession, but with the part otherwise remaining the same.

Good Fortune!

WOODEN FILE HANDLES.

mick z1a wrote: WOODEN FILE HANDLES.

Umm... yeah?

Edit:

OH! Check it out:

got to be cheaper than loads of plasters. im enjoying the thread by the way. i think these ex police bikes are great.