Testarossa's 78 KZ1000 Fighter Build

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14 Apr 2011 20:47 #444651 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build

wireman wrote: show off! :laugh:


Hey, I'm not showing off. This is my application for the new machine shop foreman at Zmax! :)

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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  • wireman
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14 Apr 2011 20:52 #444653 by wireman
Replied by wireman on topic Testarossa's 78 KZ1000 Fighter Build
the "press" in my milwaukee cordless drill press comes from me pushing on it! :sick: :woohoo:
hopefully ill here something back tomorrow about the building down the street,then ill have some room to spread out and buy some bigger tools for shop. B)

posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.

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14 Apr 2011 21:16 #444656 by rslingshot
Replied by rslingshot on topic Testarossa's 78 KZ1000 Fighter Build
Nice work Josh! Thats what I like some real detailed work keep them pics coming.

www.kzrider.com/forum/11-projects/390747-1977-kz1000-new-life
2000 Kawasaki ZRX1100
2004 Gsx-r 750
78 kz1000 basket case
81 yamaha xs 650 basket case

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14 Apr 2011 21:21 #444659 by Patton
Replied by Patton on topic Testarossa's 78 KZ1000 Fighter Build
Yikes! :ohmy: Those pilot jets were stuck in there really tight! :pinch:

Kudos for a job well done on removing them. :cheer:

:unsure: Just curious as to whether it might be beneficial to "heat" the jet block and "freeze" the new brass insert immediately before putting them together, with a view toward eliminating the need for any pressure (akin to method for bearing fitment). :unsure:

Once assembly is completed and temperatures normalize to tighten the fit, they should remain tight during service where temperature of both remains equal.

No doubt you will soon deserve your very own parking spot. :lol:

Good Fortune! :)

1973 Z1
KZ900 LTD

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14 Apr 2011 21:54 #444669 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
Well , i guess u can do it that way.


i would have just done it with my grinder. lol :P

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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~ (k) / (z)

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14 Apr 2011 22:09 #444671 by T_Dub
Replied by T_Dub on topic Testarossa's 78 KZ1000 Fighter Build
Marks fingers after cutting his nails with his grinder:


1977 KZ650B1
-810cc
-Cavanaugh Racing Head
-Mikuni RS34's
-GPR Muffler

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14 Apr 2011 23:03 - 14 Apr 2011 23:04 #444680 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
;) :) :ohmy: :cheer: :laugh: :woohoo: :woohoo: :woohoo:

Attachment 3d_clapping-49x56.gif not found


76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
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14 Apr 2011 23:06 #444682 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Patton, you are right in that it would be marginally easier to install the inserts if I had done the freeze one, heat one trick. However, if I had made the insert too big and the temperature normalized, then it could have split the boss on the thread block. This method allows some "feel" so I could abort if I felt that I was going to crack the aluminum. Now I wouldn't necessarily suggest this repair for just about anybody. I have a lot of experience assembling thin walled aluminum parts, and have learned the hard way what will give and what won't. That jet block is a very fragile aluminum part. I was surprised at the amount of porosity in the aluminum when I milled out the threads.

It really didn't require that much force to install that insert. It's a very small vice that I used to press it in with. I was able to press it in with only finger pressure on the small vice handle. Here's a picture of the vice that I used:

Attachment vice.jpg not found



The vice is only 2 3/8" wide and maybe 6" long.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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15 Apr 2011 10:49 - 15 Apr 2011 10:51 #444739 by 531blackbanshee
Replied by 531blackbanshee on topic Testarossa's 78 KZ1000 Fighter Build
oh yeah!







way to go josh.

you saved some carbs that probably did not have much of a chance any where else.

so now when you are done with them there will be no doubt in your mind that they are right.

very inspiring.

leon

p.s. this is awesome,i get my kz fix and
MACHINING PORN!!

skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
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16 Apr 2011 00:51 #444882 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Well I wasn't able to get to the mill today so I had to settle for getting the nasty Heli-coil out from the one jet block and I stripped the black paint from the caps and started to polish them. I started by sandblasting off the black paint:

Attachment 0415010741.jpg not found



Then sanded them starting with 80 grit since there were some heavy scratches under that paint. Then 180, 240, and finally 600 grit before I hit it with some rouge on buffing wheel.

Attachment 0415011118.jpg not found



I got the new pilot jets, needle jets, and jet needles today from Z1E. Thanks again Jeff! I shold have these carbs back to life in short order.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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16 Apr 2011 11:48 #444939 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build

Attachment 3d_goodjob-51x36.gif not found


Looking good bro.

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
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16 Apr 2011 18:43 #445002 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Agh ha ha ha ha hah ahahah ah ah ahah ha hhhahhh. I finally got it. Finally figured it out. I can't believe it. Ha ha hah ah ahahahahaha! :lol: :lol: :lol:

What an idiot I have been! Hahahahahaah! :woohoo: :woohoo: :woohoo:

That stupid vibration. I finally got it. Sometimes revving your bike like an idiot is useful. After I finished changing the oil, I started the bike and was listening all over the place for that stupid vibration and I found it. The damned license plate. Hahahaha! I never bolted down the lower two holes in the license plate, and it was vibrating against the aluminum backing plate. How dumb is that? Been sweating that little vibration for two months now.

Had to take the exhaust off to get the oil filter out. Gained an exhaust leak for my efforts, and I could care less. Guess I need some new exhaust gaskets.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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