Another KZP Project - APARTMENT build!

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?

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!

I salute you for saving that one from the scrap yard! Ed

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

Something to work with.
Steve

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:

If you do 1/2 as well as some of the others here you won't regret it.
Steve

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:

Looking good so far, keep at it!

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

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?

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.

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! 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