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TOPIC: Another KZP Project - APARTMENT build!

Another KZP Project - APARTMENT build! 09 Nov 2015 05:06 #697873

  • Ed_in_Miami
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I suppose I should finally get started with my Project thread.
I have been working on this project for a year now.
Family and obligations have kept progress slow, but I'm finally making some headway.
Mind you... I don't have a garage, so most of my work will be done at my apartment while the wife is away...
I have been drawing inspiration on Kiwi KZP's project which has been great, so if you're just jumping in here, I highly recommend that thread as additional read. ( )

On to my project!
THE DECONSTRUCTION
Trolling local CL I found this neglected baby, and a few bucks after she was sitting in my storage. She most likely started her work as a L.E.O. bike, but ended up as part of a funeral escort fleet.



Check out the year on the tag, Looks like she was in the elements since 1999... things that people do to these poor bikes...!


The state of the electrics... OH BOY!


On to opening the motor...
EEEK!! :(
All those years in the Miami weather mean lots of condensation and water seeping into the engine...
Cams?... totalled!



On the bright side. I had no broken screws at all. Every screw I ran into came out easily and with no drama... ;)

Will the pistons move??


YES THEY DID!!! In fact, the cylinders slid right out!! :lol:



As she sat after top end removal:



LET'S YANK THE MOTOR OUT!!! EWWWWW!

Is that diarrhea? :P

Kinda looking empty now!


Awright... let's split the case and see what's in there...


So... the balance of this endeavour.
  • Head- fixable, will need a going-over, but totally reusable... Forget about the cams!
  • Cylinders-Had been bored out to 72mm. Not recommendable to be cut further. Ebay is my friend
  • Pistons-Despite the gunky rusty appeareance they cleaned up pretty well. They are barely used 72mm wisecos. New rings and circ-clips will do!
  • Bottom end-Excellent shape! Gears and crank in great condition. Looks like all those years in the water/oil mixture kept them well preserved. I consider that a victory!
More to come!
This is my build:
kzrider.com/forum/11-projects/600312-ano...rtment-build?start=0
There are many more like it, but this one is mine... news to come!

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Another KZP Project - APARTMENT build! 09 Nov 2015 05:27 #697879

  • 650ed
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I salute you for saving that one from the scrap yard! Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
The following user(s) said Thank You: Ed_in_Miami

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Another KZP Project - APARTMENT build! 09 Nov 2015 05:50 #697881

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650ed wrote: I salute you for saving that one from the scrap yard! Ed


X2
Keep the progress up and we need lots of pictures
Dave B) B) B)
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Original owner 78 1000 LTD
Mr Turbo Race Kit, MTC 1075 Turbo pistons by PitStopPerformance , Falicon Ultra Lite Super Crank, APE everything. Les Holt @ PDM's Billet Goodies . Frame by Chuck Kurzawa @ Logghe Chassis . Deep sump 5qt oil pan. RIP Bill Hahn
The following user(s) said Thank You: Ed_in_Miami

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Another KZP Project - APARTMENT build! 09 Nov 2015 05:58 #697882

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Something to work with. B)
Steve
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229
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Another KZP Project - APARTMENT build! 09 Nov 2015 05:58 #697884

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650ed wrote: I salute you for saving that one from the scrap yard! Ed


Indeed. She probably belongs there, but I cant run away from a needy project.
In the long run, I will end up spending more than she's probably worth, but I consider it buying a Kickass bike on a layaway plan.
There is also the satisfaction of bringing back something that has been written off, which makes me oh-so Giddy! :side:
This is my build:
kzrider.com/forum/11-projects/600312-ano...rtment-build?start=0
There are many more like it, but this one is mine... news to come!
The following user(s) said Thank You: peter1958, perrykz1000

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Another KZP Project - APARTMENT build! 09 Nov 2015 06:12 #697887

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If you do 1/2 as well as some of the others here you won't regret it. B)
Steve
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

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Another KZP Project - APARTMENT build! 09 Nov 2015 06:21 #697889

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THE RECONSTRUCTION
Ok, so I expect this part to take the longest, after all, taking it apart requires no financial effort whatsoever.
This is as far as I've gone up to this point.
Remember how I mentioned this is an Apartment build? Check out my nifty parts washer!! ;)


So I designed this awesome assembly table out of a scrapped table. Cut a hole where the rectangle is, and lay it out on top of a steel table I found laying around (don't ever trust wooden legs!!). Sturdy! :lol:


Nothing like a coat of paint to make bits look shiny! :lol:




I'm kind of stuck at this stage, as I found out that my "Complete engine gasket kit" does not come with the oil passage o-ring (upper circle), or the output shaft o-ring (lower circle).
Both of them were completely brittle and in no shape to be put back in service again. Therefore, I leave this on the mailman's court, as having a leaky, low-oil pressury bike is out of the question... :lol:
Ohhh... almost forgot to mention. At some point I lost the transmission retainer "half-moons" that sit between the case and the bearings. If it wasn't for the manual, I would've not bothered to take a double look in order to figure out they were missing! Read the manual folks!! Also ordered these...
Upper case, Tranny and crank mock-up


Lower case, and oil-pan mockup.




Next steps. I will be passing by my local machine shop on Wednesday in order to have my ebay Cylinders bored to 72mm. Can't wait!!! :laugh:
This is my build:
kzrider.com/forum/11-projects/600312-ano...rtment-build?start=0
There are many more like it, but this one is mine... news to come!

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Another KZP Project - APARTMENT build! 09 Nov 2015 06:35 #697890

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Looking good so far, keep at it!
1975 Z1 900
1994 KX250 Showroom Resto
2004 KX125

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Another KZP Project - APARTMENT build! 09 Nov 2015 06:46 #697895

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Suggest taking the 4 pistons with you to the machine shop so they can insure a proper fit as these things do vary
and pistons need to have a clearance as recommended by the piston manufacture
What brand are your pistons ?
Dave
SEND PM WITH BOTM NOMINATIONS
Original owner 78 1000 LTD
Mr Turbo Race Kit, MTC 1075 Turbo pistons by PitStopPerformance , Falicon Ultra Lite Super Crank, APE everything. Les Holt @ PDM's Billet Goodies . Frame by Chuck Kurzawa @ Logghe Chassis . Deep sump 5qt oil pan. RIP Bill Hahn

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Another KZP Project - APARTMENT build! 09 Nov 2015 08:26 #697925

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Wow. I think this is the worst condition I've ever seen one in. I'm amazed none of those bolts broke taking it apart.

Are aiming to restore it to cop shape, or turn it into something else?
1997 KZ1000P (P16)
2001 KZ1000P (P20)

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Another KZP Project - APARTMENT build! 09 Nov 2015 08:40 #697930

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jackleberry wrote: Wow. I think this is the worst condition I've ever seen one in. I'm amazed none of those bolts broke taking it apart.

Are aiming to restore it to cop shape, or turn it into something else?


Yes, it was definitely in bad shape, but beauty is in the eye of the beholder.I will stay with the cop look, but add provisions for a passenger.

In order to have an achievable goal, I also want to get it running ASAP . I will probably finish it flat black, or plastidip, with plans for proper bodywork down the line.
This is my build:
kzrider.com/forum/11-projects/600312-ano...rtment-build?start=0
There are many more like it, but this one is mine... news to come!

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Another KZP Project - APARTMENT build! 09 Nov 2015 08:43 #697931

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Damn. Now I get what that thing in the kitchen is for! Strangely my girlfriend has never shown interest in rebuilding KZ engines, but still she insisted we got one of those . . :whistle:
. .
Respect to you! B) for taking on that engine rebuild, it kind of has all the things I try to avoid when buying a bike.

Seriously the case was only washed in the dishwasher? I looks so neat I thought you soda blast it. :woohoo:

//Anders
GPZ750R1 1982
GPZ750A1 1983
FZ750 1985

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Another KZP Project - APARTMENT build! 09 Nov 2015 08:54 #697934

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Street Fighter LTD wrote: Suggest taking the 4 pistons with you to the machine shop so they can insure a proper fit as these things do vary
and pistons need to have a clearance as recommended by the piston manufacture
What brand are your pistons ?
Dave


Lucked out. They're Wisecos, and barely have any use on them.
Yes, good point. I will bring them along w/ the cylinders for the machining.
This is my build:
kzrider.com/forum/11-projects/600312-ano...rtment-build?start=0
There are many more like it, but this one is mine... news to come!

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Last edit: by Ed_in_Miami. Reason: missed quote

Another KZP Project - APARTMENT build! 09 Nov 2015 09:03 #697936

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scubaanders wrote: Damn. Now I get what that thing in the kitchen is for! Strangely my girlfriend has never shown interest in rebuilding KZ engines, but still she insisted we got one of those . . :whistle:
. .
Respect to you! B) for taking on that engine rebuild, it kind of has all the things I try to avoid when buying a bike.

Seriously the case was only washed in the dishwasher? I looks so neat I thought you soda blast it. :woohoo:

//Anders


Dishwasher was the last phase in order to get rid of any loose dirt or particles I may have missed.
I did a lot of degreasing and degriming before that step, as I didn't want any oil on our wine glasses, or oil stains in the dishwasher itself. Wife may not take kindly to that. :blush:
I also used a wire wheel and carb cleaner for the tricky spots. Not easy, but definitely do-able with my limited space and "shop-resources"
This is my build:
kzrider.com/forum/11-projects/600312-ano...rtment-build?start=0
There are many more like it, but this one is mine... news to come!

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Another KZP Project - APARTMENT build! 09 Nov 2015 15:31 #697986

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Ed, you are a bloody champion mate! Nice work and really looking forward to seeing this baby finished.

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Another KZP Project - APARTMENT build! 09 Nov 2015 15:48 #697989

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What I said below - accidental double post :(
1978 KZ1000A2 Wiseco 1075 kit
1977 KZ650B1
1973 Triumph Tiger TR7V
1968 BSA Victor Special 441
2015 Triumph Thunderbird LT
1980 Suzuki SP400

Old enough to know better, still too young to care

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Another KZP Project - APARTMENT build! 09 Nov 2015 15:49 #697992

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I have to add my admiration for anyone prepared to take on such a project, While I believe I have the skills and experience to do something like this, I much prefer something I can ride and fix/modify as I go. I don't know if I would want to go that far without hearing the roar of an engine and being able to do a couple of laps of the neighborhood. Good luck.I will follow the thread with interest.
1978 KZ1000A2 Wiseco 1075 kit
1977 KZ650B1
1973 Triumph Tiger TR7V
1968 BSA Victor Special 441
2015 Triumph Thunderbird LT
1980 Suzuki SP400

Old enough to know better, still too young to care

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Another KZP Project - APARTMENT build! 17 Nov 2015 10:49 #699121

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UPS has delivered my cylinders @ pitstopperformance.
Cant wait to get them back!!! B) :lol: :woohoo: :silly:
This is my build:
kzrider.com/forum/11-projects/600312-ano...rtment-build?start=0
There are many more like it, but this one is mine... news to come!

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Another KZP Project - APARTMENT build! 19 Nov 2015 08:56 #699378

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Ed_in_Miami wrote: UPS has delivered my cylinders @ pitstopperformance.
Cant wait to get them back!!! B) :lol: :woohoo: :silly:


Pitstop were really good with helping me with some odd details on building my engine. Even though I wasn't buying a lot Joe still gave me some great advice. Top people.

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Another KZP Project - APARTMENT build! 19 Nov 2015 14:04 #699433

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Its real nice to see you saving this bike. Looking good so far. Thank you Ed

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