TOPIC:

The engine is now all apart and I have two questions.




The odometer showed 44000km. Should the cam chain and idler gears be replaced?
The insides look rather clean. I have yet to measure up the pistons and bores.

And, upon reassembly, is the kickstart spring inserted after the cases are back together? I can't see how to keep the spring locating tab in its groove as the cases are joined.

Thanks

OK, what am I doing wrong?







I can not believe the chain has stretched 0.300" over 6".
I remember reading something about link measurement somewhere here recently, but I can not find it again.

It looks like the chain has not stretched at all. Your calipers show 6.20" and the right hand leg of the calipers looks like may actually be a little past the 20th pin. The service limit shown in your book is 6.21", so your chain looks like it is well within the service limit. Ed

650ed wrote: It looks like the chain has not stretched at all. Your calipers show 6.20" and the right hand leg of the calipers looks like may actually be a little past the 20th pin. The service limit shown in your book is 6.21", so your chain looks like it is well within the service limit. Ed

I would count the right hand leg of the calipers to be on the 21st pin.
I guess that is my error.
Thanks

I think Kawasaki does not count the pin on the left as pin #1. Here's a picture form the KZ650 Kawasaki Service Manual that shows the pin count. Ed

Hi Dave Hang some weight on it for a better measurement and try using the vernier from the edge of the link to the edge of spaced link as it is easier to hook it over for an accurate reading.
Good luck. David

I have the cases back together now.










And I bought some of the SS caliper bolts from Webike. They are quite nice.

It has been a long time coming but the engine is now back in.
I bought the points cover and base from Kawasaki. The finish on them is like a brushed finish.
Is that correct for a Z1-R?
Also, has anyone bought the repo covers from Z1 Enterprises? What kind of finish do they have?

Very nice work! That is a thing of beauty! "Art" to look and stare at! I have to ask? Are you going to sand the fins to bare aluminum?
I have a gloss black engine also, nothing stock or original. I powder coated all the engine covers and am using polished SS hardware.
I better finish this thing, before I kick the bucket. And my kids sell it all at an estate sale for $100 for all the motorcycle junk!

Kawasaki stopped producing that gasket kit in that green package sometime around 1981 or so. Do yourself a favor, and make sure the gaskets in that kit are not hard and brittle. Those gaskets are like 35 odd years old already. Most likely they must be like house bricks by now.

I worked in Kawasaki dealerships back then, and I remember when they closed out those gasket kits in the early 80's!!!!

z1kzonly wrote: Very nice work! That is a thing of beauty! "Art" to look and stare at! I have to ask? Are you going to sand the fins to bare aluminum?
I have a gloss black engine also, nothing stock or original. I powder coated all the engine covers and am using polished SS hardware.
I better finish this thing, before I kick the bucket. And my kids sell it all at an estate sale for $100 for all the motorcycle junk!


Yes, I do plan on sanding the fins.

Does anyone know what the resistors in the lighting circuit are for?
Is Kawasaki trying to reduce the voltage to the lamps?
From 12 V at the battery, I have 9 V at the headlight and tail light.
I have measured all the switches in the system and non of them have a high resistance.
I have tried bypassing the Reserve Lighting System and end up with the same voltage drop.
Am I trouble shooting a non issue?