KZ650 Sleeper Build (KZ1000 engine transplant)

I started back on this today after a bit of a detour.

I ground some bigger chamfers on the liner bottoms in anticipation of installing the pistons. The chamfer I put on with the lathe got mostly removed due to the heavy cylinder boring required. I was not aware I needed to chamfer the ID right to the edge of the liner OD.  

All that was left of the original angle would not have been enough to easily install the piston rings.

I ground the liner edges by hand with a big carbide burr chucked in a hand drill.

 

I made this centering plug for the AFR probe to attach to the RH muffler I will be using on this build.





I just need to drill some more holes in it to let the exhaust gasses pass, those flats got milled on OD to be able to clamp it in a vice for drilling.

I also made up a mount rail to attach it to the muffler bracket.
 

Got my used MTC pistons cleaned up and installed new NPR rings on them.



They have been around the block but they are good quality pieces so glad to have them.

The rings I found thru the Hastings catalogue by cross referencing thickness VS bore size. They were listed for a 1.6L Nissan Pulsar car engine, quite a bit cheaper than MTC/Wiseco equivalent.

I also trial fit my base gasket and found I needed to trim a few spots, but now it fits perfect.

Not sure when I will be installing the top end. I think I want to build the bike on the ground first as its easy to get down off the cart right now without the addition weight of the head and barrel.


 
 

I finished drilling the holes in this centering plug for the O2 sensor fixture. I added some M6 threads to pull on it in case it gets stuck in the muffler opening.



Just one more thing put to bed so I am not caught scrambling when its actually needed.
 

Looking at installing the new Shinko 230 tires I bought. Decided to start building the frame up on the garage floor instead of yanking my drag bike off the bike lift.



The old Kendas are from 2012 but they don't have that many miles on them. They did pass a safety check a couple of years ago.
 

I like mine. 
Steve

rumble.com/v3uvxff-shinko-tire-balance.html

 

I decided to put the clutch pack on the engine, but I need to soak the fiber plates in fresh oil as they have not had oil on them for a lot of years.



I also put the holes in the oil cooler bracket, only thing left to do on it is saw cut and mill some flat edges to match the profile at the top of the frame.



This is the last fabricated part required that is going on this build.
 

It was cold and snowy here today so had a bit of time to work on this cover.

Went from this







to this



in about 10 minutes with a aluminum file and some 80 grit paper. I was able to get all the big gouges out pretty quickly.

Just need to spend more time hand sanding it now working from 80 to 400 grit, see how it goes.
 

Spent a few hours today removing paint on the cam cover and cylinder head. Cam cover is complete but still need to sand and polish the ends. The head still needs some work so will try to get after it tomorrow.

The weather is getting better so no excuse not to assemble the bike.
 

I was thinking about pulling the frame/engine off the work cart. The cart is at waist level, thought about just grabbing it then doing a one way squat. Stopped squatting about 3 years ago so figure I should not chance dropping it. I currently weigh in about 185 LBS.

I figure its about 250 LBS but very awkward to hold on to. The last time I took a frame/engine combo off the cart was my Z1 drag bike back when I was squatting, was able to handle that as it was probably 25 LBS lighter and when I was in "shape" (back squatting 285 LBS for 3 reps) Having something on your back and holding it out front are completely different strength positions.

I ended up buying this little chain hoist :

Its good for 550 LBS. I already have a place to hang it out on the garage ceiling and can wheel the cart under it. This solves that problem for good, no more busted back.
 

As we get older we need to embrace mechanical aids, it ain't worth hurting yourself or the bike 

Agreed.  I've come to realize that the days of lying under a vehicle with a transmission on my chest, trying to line it up with the clutch and  bellhousing are long gone.