Building a GPZ1150 from a CSR1000

Today I plan on Molly coting the skirts and Ceramic plating the crowns on the pistons. This means that I can pull off the top end tomorrow.

It sounds like your still having fun anyways.
Good luck.

I finally did some cam fitting. Since I no longer have access to a CNC machine I had to do it the old fashion way, with a dye grinder. I hate to do work in such a sloppy way, but I guess it will be functional and no one will know except me. I am really shocked how much space there is (or rather is not) for clearances with these new high lift cams.

It must not be forgotten that this is a late model GPz1100 head that was already pretty radical.

Well- I discovered a problem. Somehow my new cylinders, that I just got bored by Pitstop performance, I bent the lower skirt of one of the outside cylinders. I attempted to straighten it out, knowing very well that it will most likely not work. After I succeeded making the lower lip round again, I checked it very carefully to look for what I already knew I was going to find, a crack about 3/16 of an inch long. Well, I was not going to install a new sleeve and have it re-bored, nor was I going to leave it there to continue creeping up the sleeve. Here is my solution.

I figured that if Kawasaki can manufacture a sleeve that looks like this, than mine is 1000x better and safer. If you will notice the red line on the sleeve in the picture, it is a crack. No wonder with sharp corners.

Well done Otto. Well Done!
I'm sure u will be fine. No problem. Sometimes sleeves need to be clearanced like that for strokers, so they clear the crank.

That is exactly what those square notches are on the 1300 sleeve. The 1300 is a long stroke engine where the stroke is longer than the bore.

Last night, I went to my brothers house to help him with his Zephyr 750 he put the engine back together and wanted me to check everything out before we fired it up. We did start and ran the engine for a while on an auxiliary tank. I never realized how cold blooded the Keihin carbs made it. It runs like crap until it heats up. Those carbs are real junk. Unfortunately because of the space restrictions due to the frame, Mikunis are out of the question.

otakar wrote:

It runs like crap until it heats up. Those carbs are real junk. .

that Would normaly mean they are jetted tooo lean on the pilots?
What carbs are they??

otakar wrote:

Here are the pictures I promised.
1

that turned out really nice!

otakar wrote:

I figured that if Kawasaki can manufacture a sleeve that looks like this, than mine is 1000x better and safer. If you will notice the red line on the sleeve in the picture, it is a crack. No wonder with sharp corners.

If this is a crack how will the notches help?