1980 KZ1000E ST project

Well at least the hole in question has good access. It's not the one close to the block. U r right it should come out. Once out of it's a pain I can take the top case to the machine shop if it give me trouble. Much lighter. Don't want to mung up the mating surfaces on either the case is the cover. R

Good news, I got the starter out. Bad news, the drill walker and bit the case and then I busted the extractor even with hand pressure. What a bitch with the clutch hub nut. I am not sure if it was improperly staked or just on there so long is was extra stuck. Any it's off. Cannot free the rotor. I have the puller but it is a hollow one and I did not want to bugger it up. I would like to get it off as while I am this deep. To do engine seals it's gotta come off. After I split the cases I can take the top case to a machine shop for extraction. I may try some drilling of my own, but it's delicate. Pics later R

Well, a bit of a set back. :dry: I was making progress on the bolt drilling and when I put in an extractor it broke the thread bung. not through but now definitely need the machine shop. I suppose they can weld on a 6mm bung in its place. That's my guess anyway. Cases are split, all guts are sorted and now I can clean, polish ans paint cases. Going on vacation a while so may not be much progress the next few week. Will be ordering all the engine seals, gaskets, orings, etc. May get to valve lapping. I need four shims to put all my clearances at .12 - .13, clutch nut, bolt cleaning and much more. Once I clean the frame I will know if it needs paint or not. Wow this is fun !!! R

That's why I don't like extractors especially on small bolts. I have a set of reverse drill bits. I've busted a few easy outs in my day. PITA.
Steve

Amen to that, Swest.

Found a competent shop to tig and retap the starter bolt mount hole. Stopped a a few times and then got referred to the TIG guy with a milling ability. Nice guy, said no problem, it wont look as pretty but it will be structurally sound. R

So more clean up. Man this bike has been neglected. All carb holders were cracked up and RTVd several times. Got the case bolts cleaned up. Working on gasket removal. Any short cut on the head gasket? It came off the case nicely, but it is hardened to the head. Also I know the machine has a roller crank, but some of the case journals are discolored and minor blemishes. I do not think its enough to affect holding the bearing cases on the roller bearings. I'll get some pics tonight. Gotta run now. R

Some pics
R

you could get Phenolic pistons for $44 per, they are super light and heat resistant. a solid upgrade to the brakes.
if you poke aorund on this site he has both the 38mm and 42mm pistons.

www.vinmoto.org/gallery/v/VinMoto-Garage...+Kawasaki+KZ+65+900/

Why did you take engine apart?

It's 35 years old. Will get new bottom end and top end seals, gaskets, orings etc. Will be good for another 50k. No apprehension about it. Dissassembly causes me no concern. Also the clincher was needing a top case welding repair on the starter bolt mount I busted. Wasn't toting the enigine around to a shop with the crank and tranny in there, still about a 100lbs. Plus it's fun. YMMV. R

To do things right. Pic of the broken bolt?
Steve