TOPIC:

Looking good!

Good job Nils.
Kick spring, if there's tension still on the spring, you got it right.
Idler shaft. It should have a copper washer facing the cover.
Shifter springs, no better time than now to replace them. Get the late model shift spring.
Steve

swest wrote: Good job Nils.
Kick spring, if there's tension still on the spring, you got it right.
Idler shaft. It should have a copper washer facing the cover.
Shifter springs, no better time than now to replace them. Get the late model shift spring.
Steve

Thanks Steve.

Looking at the cover, I see that there is a recess that that shaft (A) rests in, I will lube it just for ease of assembly, but I do not see any washer called for on the parts fiche. Safe to assume you meant the copper washer visible here in this photo marked B?

When you say "late model" are you referring to the 1975 "B" bike? Or something later in the KZ series?

TIA for the wisdom,

Nils

Shaft A should have a thin thrust washer. Late I mean KZ 1000 shift lever spring. They have extra winds so they last longer.
Steve

swest wrote: Shaft A should have a thin thrust washer. Late I mean KZ 1000 shift lever spring. They have extra winds so they last longer.
Steve

Well I don't have it and I do not see it on the fiche, Not going to worry about it. Thanks though.

swest wrote: Good job Nils.
Kick spring, if there's tension still on the spring, you got it right.

Just for the benefit of the next person looking for reference, let me fill this in a little better, as it's not quite that simple.

This is my disassembly photo:

The best technique for getting this oriented properly is as follows, more or less as described in the manual, but for clarity:

Install the kickstart shaft, close the cases, etc.

Temporarily install the splined base of the kickstart lever assembly to actuate the shaft, and turn it CLOCKWISE till it stops. Unless you happenned to install it in the perfect location, it will rachet-click several times till the pawl on the shaft comes to rest on the steel stop that is bolted to the case interior. WITH THE ENGINE INVERTED as is normal for reassembly, the hole IN THE SHAFT OF THE KICKSTART MECHANISM should be oriented at roughly 10:00 as shown in the above disassembly photo.

Insert the kickstart return spring with the pointy end into the recess between the case halves.

Grab the opposite end of the spring with your biggest, pointy-est needle-nose pliers and twist the spring about 180 degrees COUNTERCLOCKWISE so it can be inserted into the hole in the shaft. Have a big screwdriver in your other hand to lever it into place.

Insert the alloy guide between the spring and shaft.

When you're finished it should look like this, and the lever base should install nearly parallel with the back edge of the engine case.

Hope that's helpful to someone down the road.

N.

Where's the LIKE button on this forum ?
Thanks, I think that'll be helpful,
Pete

i find the engine being upside down in the pictures to be dis-orienting.

but ,
i have never givin much thought to these.
i always just pulled em and stuck em back in how it seemed like they went and they worked.

i am sure you will be just fine.

how did you go about removing the gauld marks on the crank?

it turned out very nice.

leon

531blackbanshee wrote: i find the engine being upside down in the pictures to be dis-orienting.

but ,
i have never givin much thought to these.
i always just pulled em and stuck em back in how it seemed like they went and they worked.

i am sure you will be just fine.

how did you go about removing the gauld marks on the crank?

it turned out very nice.

leon

Heya Leon,

I used a 1-inch strip of emery cloth and afew drops of oil, and polished it like a wingtip shoe .

NobleHops wrote: Heya Leon,

I used a 1-inch strip of emery cloth and afew drops of oil, and polished it like a wingtip shoe .

lol perfect!

k.i.s.s.
man after my own heart,nice work

leon

Lots to catch you guys up on, but here's the first firing of the bike yesterday

Happy new owner

The guy that built it

More soon, I will catch up with a wrap-up, just flat out at the moment.

Sincere thanks guys, you were a great help.

Nils Menten