Phoenix Fighter

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22 Jun 2015 12:56 #677777 by 79MKII
Replied by 79MKII on topic Phoenix Fighter
Thanks for the help! Now back to the regularly scheduled build thread..... :)

The Kaw List:
Current: 79 KZ1000 A3 MKII, 78 KZ1000 A2, 78 KZ1000 Z1-R, 78 KZ650 SR, 80 KE175
Former: 03 KLX400SR, 99 ZRX1000, 82 KZ750 LTD, 80 KZ1000 A4 MKII, 80 KZ1000 LTD, 78 KZ1000 A2, 74 H-2 750 Triple, 78 KL250

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22 Jun 2015 14:42 #677785 by kaw-a-holic
Replied by kaw-a-holic on topic Phoenix Fighter

79MKII wrote:

kaw-a-holic wrote: ... It was really easy. was concerned about it working at since I couldn't use the applicator to get the Helicoil in the hole due to the shoulder. Just like you said Steve. ...

I'm having this same concern right now myself. I have an M6 thread that I'd like to heli-coil but fine thread heli-coils are supposed to use that pre-coiler or whatever they call it. The hole is where a knock pin goes, so it's basically countersunk....can't get that tool in there. These can be wound in by hand? Is that what you guys are saying? I wanted to try it but once it's drilled, there's no turning back. You weren't able to install the heli-coil without removing the head, were you?


Took the head off, left the cylinders on. I used just the threaded rod that cam in the kit. Trust me it didn't just go in. I held it as straight as I could applied downward pressure, turned and hoped for the best. I didn't have anything to loose. The old threads were wasted,
Worse case is I would have just tapped it and ran a bigger bolt.

Jon
1977 KZ1000a1
Mesa, AZ
Phoenix Fighter Project

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22 Jun 2015 14:49 #677788 by kaw-a-holic
Replied by kaw-a-holic on topic Phoenix Fighter
Bad news boys. The motor has to come out. There is something scrapping on the inside but I can't see. I can not make a complete rotation without is binding up so its time to split the cases. The good news is now I can correct a couple of things I wasn't to keen about anyway. Almost made it, almost. :pinch:

Hey! Now I can get my crank welded. Do I need to ship this to an expert? OMR if you are reading this have you had any cranks welded in AZ?

Jon
1977 KZ1000a1
Mesa, AZ
Phoenix Fighter Project

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22 Jun 2015 15:00 #677789 by SWest
Replied by SWest on topic Phoenix Fighter
A good welder can apply a 3/4-1" bead along the pin and crank throw. That's all you need. The rod side play should be checked. Kawasaki did a good job on these cranks.
Steve

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22 Jun 2015 15:05 #677791 by SWest
Replied by SWest on topic Phoenix Fighter

kaw-a-holic wrote:

79MKII wrote:

kaw-a-holic wrote: ... It was really easy. was concerned about it working at since I couldn't use the applicator to get the Helicoil in the hole due to the shoulder. Just like you said Steve. ...

I'm having this same concern right now myself. I have an M6 thread that I'd like to heli-coil but fine thread heli-coils are supposed to use that pre-coiler or whatever they call it. The hole is where a knock pin goes, so it's basically countersunk....can't get that tool in there. These can be wound in by hand? Is that what you guys are saying? I wanted to try it but once it's drilled, there's no turning back. You weren't able to install the heli-coil without removing the head, were you?


Took the head off, left the cylinders on. I used just the threaded rod that cam in the kit. Trust me it didn't just go in. I held it as straight as I could applied downward pressure, turned and hoped for the best. I didn't have anything to loose. The old threads were wasted,
Worse case is I would have just tapped it and ran a bigger bolt.


A tap is self centering more or less. As long as it goes in straight and you stop when too much resistance is felt, back off a little, and cut some more, it will turn out well. A little oil helps prevent galling of the threads. I always use oil when drilling or tapping threads.
Steve

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23 Jun 2015 17:36 #677994 by kaw-a-holic
Replied by kaw-a-holic on topic Phoenix Fighter
I'm going to pull the cylinders back off and do a double check, I really don't want to pull the cases. I am not sure I can get it all back together. The transmission is what really makes me apprehensive about splitting the cases.

Jon
1977 KZ1000a1
Mesa, AZ
Phoenix Fighter Project

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23 Jun 2015 17:42 #677995 by SWest
Replied by SWest on topic Phoenix Fighter
Piece of cake. nothing is going to go sproing on you.
Steve

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23 Jun 2015 17:47 #677998 by missionkz
Replied by missionkz on topic Phoenix Fighter

kaw-a-holic wrote: I'm going to pull the cylinders back off and do a double check, I really don't want to pull the cases. I am not sure I can get it all back together. The transmission is what really makes me apprehensive about splitting the cases.

A fear grossly exaggerated by the uninitiated

Bruce
1977 KZ1000A1
2016 Triumph T120 Bonneville
Far North East Metro Denver Colorado

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23 Jun 2015 19:43 #678014 by floivanus
Replied by floivanus on topic Phoenix Fighter
+1, there's only two shafts, three shift forks and the shift drum, nothing really.

my bikes; 80kz1000(project), 77 gl1000, 74 h2 (project)
Past; 78 kz1000, 83 kz550
Andrew

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23 Jun 2015 22:14 #678040 by kaw-a-holic
Replied by kaw-a-holic on topic Phoenix Fighter
Thanks guys, I appreciate the encouragement. I wI'll feel better about going through. Would really like to take a look at the crank and rod bearings.

Jon
1977 KZ1000a1
Mesa, AZ
Phoenix Fighter Project

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24 Jun 2015 01:37 #678046 by floivanus
Replied by floivanus on topic Phoenix Fighter
The only check for the crank and rod bearings are a simple wiggle test for the rods (not 100% sure on this next one) and a side clearance check for the crank bearings.

You may also want to check the small shift fork rod, theyre supposedly easy to bend and the later 77 and early 78 I had someone did a poor job cutting the circlip groove at the end of the shaft. Which made it so the shaft could slip and trash 2nd gear on me.

my bikes; 80kz1000(project), 77 gl1000, 74 h2 (project)
Past; 78 kz1000, 83 kz550
Andrew

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24 Jun 2015 06:14 #678063 by SWest
Replied by SWest on topic Phoenix Fighter
It would also be a good time to back cut or have your tranny back cut. 2nd. gear is the most used power gear. It is the first to go. Two years ago I did mine but it had high miles on it. It had been popping out of gear and back cutting it solved that problem, not for long. Knowing of a up coming problem I bought a low mileage tranny. After about a year my old one started to act up and I had my new one back cut and ready.Took one day to yank out the motor, the next to put in back in, grumbling the whole time. The main shift fork is the biggest issue on the Z1's. A KZ 1000 is beefier so I changed the forks and drum. I got them from The Old Kaw Man. I suggest changing the shift return spring also to a 4 wind. The older models had 2. Best to do it now than later.
Steve

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