Some assembly required. 1996 Kawasaki GPz1100

Do you still have the pics on file?
Steve

Yes, I have a folder on my notebook with all of the pic files of the bike. It also contains the pdf manuals that sorrocco emailed me for this 96 GPZ. I need the ability to edit my posts to try to repair the posts. Bill has been in touch via private email. This is a major crash affecting the site's informational value. As often said, a picture is worth a thousand words.

I am preparing to disassemble the original engine case. No holes, and the rod is just loose, not through the side. Hopefully this crank can be fixed / saved on the cheap.

It looks like after uploading all of the missing attachment files to bill's google cloud folder, he and Anita have been clicking their fingers to the bone. (thanks Bill!) They restored no less than 50 missing attachments to my dead GPZ thread. To tell the truth, it is quite disheartening to find all of the pics missing. Kudo's to the KzR staffers!

Sooo.. I hope it's safe to continue to document my project with pics. And to tell the truth, the encouragement and comments is helpful in sorting out this basket case. I also listed the 6 speed for sale on kzr and on STL CL, along with on the zrxoa web site. I need to sell of some spares to finance the crankshaft repair. The zrxoa web site is a whole new ball game as far as posting pics., so I abandoned the pics only to ad a link to my CL ad.

My CL ad: stlouis.craigslist.org/mpo/7032729922.html

I finally disassembled the original engine that does >not< have custom ventilation. The bearings look worse than the parts donor engine. Also the same misalignment of the #3 main bearing insert. At least KHI was consistent. I can't believe QC let this slide! This whole lube oil system is a complicated mess!


The big end of the rod is still intact, but I am willing to bet is is wayyyy out of tolerance.


I tried to number stamp these rods, but that is some hard metal. I think I ruined my number stamps trying to number these rods.


The crank looks mucho better, yet still about .015"-.020" smaller (1.395") than the other 3 rod journals. (1.416") using my veneer calipers for measurements.



The down-stroke side of the journal.

KZR is heavy on the pics. That's one of the best features of this site. To keep this from happening again Bill is looking into more space and how much it will cost. That's why the donations are so important.
Steve

I agree on the donations Steve. This site is not self-sustaining from vendor advertising revenues. There are a few vendor ads, but not near enough. Bill has to be independently wealthy to pay for all the expenses involved with kzr. I must admit I haven't donated as much as I'd like to. This bike project, along with the free estimates / quotes don't pay so well.
More data space hogging pics to follow:
There must be 100 o-rings in these oil tubes, orifices and passages. Bottom view of the ZX oil pump / oil filter area with the pan removed. The #3 main bearing cap is pictured down inside the case with the J-tube still inserted in the feed hole. It is the one main bearing cap that does not attach to the lower case. It goes on before the lower case. this is also the main bearing that feeds the #3 and #4 rod bearings. I don't completely understand why the #3 rod shucks while the #4 rod lives on. Hmmm.


The oil pumps (plural) A gerotor pump is located on each end of the shaft that also drives the water pump on the drive end.


The crank from my ventilated engine. (has red paint on crank gear) #4 looks good in this motor too while #3 is totally screwed.


This is about the most beat up crank journal I have ever seen. It's no wonder the rod decided it no longer wanted to occupy the same space. OR, as they might say of it on a fleabay auction.. removed from a good running engine with a barely noticable "tick". :S