Saving a '81 KZ750-E

Back at it after a trip to the east coast for a week. Before I left, I applied the Permatex Liquid Metal filler so it would have plenty of cure time. I tried sanding it down today and did not get very good results. I am altering my application method since this stuff starts to harden very quickly when exposed to air. It is a thinner liquid than I was expecting, but cures really quickly. After cleaning the entire surface, I started to fill and smooth small areas at a time. This looks like it will sand down much smoother. I will give it another day or two and try another sanding. I am going to use a finer grit paper this time around as well.

I was glad to hear two of my part shipments won't arrive until tomorrow. I was afraid they would be left on the porch while I was out of town. I asked a neighbor to keep an eye out, but the tracking is saying delivery tomorrow.

The clutch inspection revealed all the parts are in very good shape, and well within service limits. I had expected this to be the case, actually. Knowing the original owner, and how easy he rode this bike (not a racer type, more of a commuter and cruiser) I didn't think the clutch would have excessive wear. A new roller bearing, and lock nut for the clutch hub are on the way. Parts are clean and waiting for the rest of the parts. I should have the bottom end back in the frame inside of the next week.

The second attempt yielded much better results!


Another cleaning and I should be ready to paint.

I didn't catch all of the pits, but I got the majority of them. I'm happy with the results this time. Three coats on, the site glass will get replaced in two or three days.

The piston ring compressors showed up. Should get one more package before the end of the day.

First look with the new SS case hardware. Perfect amount of bling, if I do say so myself!

More stuff showed up!

Mikey likey

I have a feeling your ring compressors are not going to work out. Don't think you will have the room to use them. If you don't have the fancy Kawasaki ring compressor tool, you do two pistons at a time.

Here are two photos of the Suzuki ring compressor tools being used on some 73mm Kz1000 pistons. You do the two center pistons first, then do the two outer pistons when you use this type of ring compressors. It took me like 2 or 3 tries to get the center two pistons into their bores. After that the outer two went in on first try!!!!

You might have to use something like these Suzuki ring compressors to get your pistons into their bores!!!

I had the same concern in the back of my mind when I opened one up. The are a bit tall. Ah, well... another bridge to jump off of when I get there. As soon as the bearing and lock nut for the clutch hub get here I will be able to get the clutch and cover installed. Then the bottom end goes back in the frame.

The new hardware works well with blacked out case covers.

Using some wood for support, and my wife's help, I got the bottom end back in the frame.

This is amazing!
I wish I had the skill, exp, means and space!!
Cant wait till its done