Freebyrd's 81 KZ1000 Build

freebyrd as far as you and i are concerned,yes.
i am sure that there is some chemical properties that are different but either one should be fine for your needs.

leon

Thanks Leon! I did a little searching on the web and it seems there were a couple of toxic components in the 1104 but they made it safer and now it is known as 1194 and should work the same way. thanks!

Here's a picture of my "spacers"

wow,freebyrd they could almost be steering stops .
as long as they are solid and clear everything they will work until you want to change them.

good job,

leon

I can chop the other stops off now! Haha good call!

It does look a little goofy, though you wouldn't see unless you looked for them. I'm kind of going for that theme of a mechanics special. Probably will never be a show stopper with my skills, but a solidly functioning bike that works well is what I am going for at this point.

but that always changes as the project goes on....

wrist pins are very accurate on there dimensions.i used to use four of them to space stuff off the mill table until one time i was milling the top of a little two stroke 85cc cylinder i had just sleeved.as the flycutter was moving across it i watched one of the wristpins danced out from under the cylinder and before i could stop the machine the cylinder fell over and the fly cutter took three huge swipes out of the deck of the cylinder :ohmy: :blush: .
it is junk,i bought the customer a brand new cylinder and decided that i would not use them for that anymore :silly: .

i do use them as spacers on the bolts for my torque plates that i bore and hone harley cylinder with tho .

leon

freebyrd24 wrote:

Thank you for the pics and info Mark! That's a good idea to cut off the top of one of the rubber tapered dampers and just use that. So you have the top of that rubber piece on top, then are you still using a rubber damper underneath?? I'm going to get some time to try it this weekend I hope. I'll try to put the rubber damper underneath, then a spacer.
Thanks!

i put the tapered rubber underneath as well. i installed it with the big end up. when u take your arm to a fab shop for welding , u could get them to cut the bar riser bolts down to size and re-thread them. or u could buy a die and do it yourself.

Quick question, is there any preferred way to put the sealer on? I picked up some sealer for between my cases and the cylinders. Should I still use the gasket that goes there? Coat both sides of the gasket with sealer? One side only? No gasket at all?

I just really don't want to have to take it off again due to a leak so I want to get it right now.

Thanks!

there is no gasket between the cases???????

There is a gasket there now, but I had a leak when I first put everything together. The leak was between the case and the cylinder on the left side where the kickstand is.

OK , thats dif. u said between the cases. the gasket between the upper case and cyl has a gasket. just put the yamabond/3 bond ,what ever u got, on both surfaces and away u go.
the tricky part is getting the cyl over the pistons without making a mess.
give it some thought and u will come up with a plan. i put the glue on the bottom of the gasket , put gasket in place, put cyl on top until it sets. then remove the cyl. place 2, 1/2" THICK STICKS AROUND #2 AND 3 CONNECTING RODS TO HOLD UP THE CYL. U MAY HAVE SEEN A PIC OF THIS IN YOUR MANUAL. THEY ARE ABOUT 2" WIDE , 5" LONG, AND U CUT A U OUT OF THE CENTER TO FIT OVER THE CONNECTING RODS. LOOKS LIKE A TUNING FORK WITH NO HANDLE.
put a rag over the holes so u dont drop a circlp in there.
THEN START PUTTING THE CYL AND PISTONS TOGETHER. WHEN U GET THE CYL OVER ALL PISTONS U WILL HAVE THE PISTONS ALL ALIGNED LEVEL AND THE CYL WILL STILL BE SITTING UP ON THE 1/2" STICKS. NOW U CAN REMOVE THE STICKS, GLUE THE TOP OF THE GASKET (NOT EASY TO ACCESS), THEN LOWER THE CYL.

Made some good progress this weekend!

Because I want to actually ride it this year, and because I seem to never have enough time to work on the bike, I put the stock rear end back on for now. I figure next winter or later on I can figure out my sprocket offsets, shock mounts welding to swingarm, etc...

So I have the motor in, put my sealer on, put the cylinders back on, put the fresh head on from Larry (which is far too nice to even put on this bike, thanks Larry!), and torqued it all down.

I have front and rear suspension and a motor that's almost back together! :woohoo: :woohoo:

I have to set the cams and timing on the cam chain up, but I've done that about 10 times already so it shouldn't be a big deal.

Good to actually move forward though! I'll try to get pics up, if not, then this weekend. I ordered some new cam end caps and a valve cover gasket and I should be good! Springs around the corner...