Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000

Nessism wrote:

Checking valve clearance with the lobe pointed away from the bucket, will result in the measured clearance being greater than if measured using the factory method by a thousands or two. 


Thanks Nessism,

I'll try to remember to check the clearance the same way after running her for a bit.

Do you think the difference between the two clearance check methods is due to the camshafts rocking around a bit in their bearings, or truly being on the base circle of the lobe?
 

OK then.  Looks to be stock.  I checked mine and it's a little different.  No bolt through the center and the top is solid.  


www.partzilla.com/catalog/kawasaki/motor.../cam-chain-tensioner

 

Summer is ripping by too fast while I was waiting for some gaskets, valve cover and clutch cover.

Today I semi-installed the valve cover casket.  Semi-installed as I've not really tightened things down yet, just snugged.

The four rubber end caps, I reused, and gooped the circular section with some of the Permatex #58922.  The package is gooped up as I put a bit there to monitor cure time.  If you get this goop on your hands, it's there until epidermis shedding sloughs it away.

Next step is to recruit my strong neighbour and "frame the engine".

Once in the frame I'll lean the engine hard left to minimize oil spillage and renew the clutch cover plate, which I think, like the valve cover, is just orange silicone without a gasket.

Hopefully my progress will be less sporadic the Fall.

Thanks guys...............
 

The engine is framed !!

I had a young strong backed crew over yesterday morning, and we shoehorned the engine into the frame without too many paint scratches.

It'll take some careful planning on the best way to to build her up onto the wheels.  Perhaps the swing arm next, then the forks.

I had an engine lift which would be useful at this point, but it's on long term loan to an unknown location.

I think your engine lift may be in the same black hole my engine hoist disappeared to !  

Scotty

I must be at the other end of the black hole because I have 3 engine hoists and 3 engine stands. I've never even bought one in my life.

On the subject the next thing I install is the centerstand so I can put it on the lift table, block up the front and strap it down.

Kelly,  does one of them have a leaky hydraulic ram ?  I think that one may be mine, haha  

Scotty

Kelly E wrote:

I must be at the other end of the black hole because I have 3 engine hoists and 3 engine stands. I've never even bought one in my life.

On the subject the next thing I install is the centerstand so I can put it on the lift table, block up the front and strap it down.

Thanks Kelly E.  The centerstand is a good suggestion.  Nice looking clean up on your engine.
 

I had a bit of time to re-seal that engine case clutch cover that was installed with the ugly orange silicone and no gasket.

Leaned the frame engine unit hard to the alternator side to prevent oil spillage, which worked well.

Not stripped threads, but I did have to use a an M6 1.0 tap to clean silicone and dirt out of the threaded holes.

Clutch looks fine to me so I'm not inclined to take it apart and clean and inspect the plates, which might proven to be a regrettable decision.

Can we interpret those four etched lines on the clutch gear?  At the red arrow head.

She's pretty clean on the inside, with just a wisp of soot on the bottom of the case.

The oil level sight glass was dirty, but wiggling a wee paint brush around through the holes restored its clarity.

Feedback appreciated.............

 

Sorry, I can't help with the hash marks on the clutch basket, but the leaning over of the bike to service the clutch is a time honored tradition. Couldn't tell you how many times I've seen it done at the race track. Good job!

Buttoned up the clutch cover today, hoping that everything within is A-OK.

I ordered the wrong gasket, so made my own with some high quality gasket sheet saved for just such purposes.

And gooped the sealing surfaces as this holds back engine oil that is being thrashed harshly by the spinning clutch.

I'll wait 2-days for the goop to cure, then tilt back the frame/engine unit.

Meanwhile, I'll see if I can get the swingarm in.

I think I painted myself in a corner regarding reassembly, but my friend has a chainfall that he uses with a 4 by 4 in the garage attic manway.

Coming along nicely