1981 KZ550A2 Update

Now you have no excuse not to do it. :lol:
Steve

The foundations been laid and the plan is made. I am all in, just need to get some weather warmer than single digits to start. I have the work place cleaned up with space for parts removal and bagging of hardware. Tools cleaned up and sorted. I have my lift ready to slide out the engine onto it and up to the stand.What's it was 120lbs? I'll put some towels on the frame jack her up to clear the frame rail and slide onto the lift. Ready. R

Don't you have a heater out there? I've got a propane one that blasts heat.
Steve

There is a small electric, but it's a three stall uninsulated garage, so I need at least 20 or so to be comfortable.

R

Well, put on the little heater and hit the frigid garage for a few hours.My goal was to get it out of the bike and into the K&L MC25 engine stand. Success. I had hit most of the fasteners with penetrating fluid a few days ago. I did not have any issues with broken fasteners.

I did find that likely it was me that crushed the dynamo wires in the upper area of the sprocket cover. It will need some TLC to get it right. I was surprised it didn't cause a bigger problem.

Dissassmebly was fine. The hardest issues here were carb removal. Major PIA on a 55o. I may hit pods and new pipes when going back together. The 550 is not a CV carb and smaller motors seem to have less problems. Also Loudvhx has a great write up on shimming the needle, mains are likely not needed, will see. The secondhardest part was getting engine to the bench. I just picked up and carried it and that was not a great idea. I ain't getting any younger. :huh:

Otherwise I was able to invert the stand bole the motor on and tip the stand on its base. good deal.

I did have one signnificant fk up. When mounting the engine to the stand I didn't account for the fram spacer welded in. I ran one of the mount bolts to bottom thread and stripped the bolt on the nut. Ground out the bolt heads only to realize there is a boss there to hold the jam nut and now I have no bolt head either. I drilled the nut and cold chiseled it off. Went to the hard and got the exact bolt and jam nut. Back in business.

Anyway here's a few pics. Any input appreciated.

R

Tearing into it I see. This is the kind of heater I was talking about. It CRANKS. I left it at my daughter's place last year. Sitting in front of it you'll cook.
Steve

Is that heater safe to run in an enclosed area?

Today was an easy dismantle. The more careful part is upcoming. I'll wait for some better weather and it's coming next week. February Jan and Dec all average below frezzing for a high temp here. I am gonna check that out. I've used some ice fishing propane ones, but was unsure if the BTUs would be there. Also don't want to blow up the garage. :blink:

On the way there.
R

17,000 BTU's. As long as the space isn't air tight like in a garage, it isn't too much of a hazard. I'd keep a window cracked and of course no open flammables. During the summer in 13, I brought it inside and worked on it at my leasure. :whistle: The dirty stuff I did outdoors, cleaned them and brought them in. By the time my parts arrived, everything was clean, painted and ready to go. In my case I left the head off and rolled the case out to the shed on a dolly. In my 20/30's I'd puck up that engine, not now, a strained back would only set me back more time. I wanted to RIDE and I did just that. :woohoo:
Steve

More done. All I have left is removal of the oil pump, secondary shaft and pull the flywheel before the split can happen. All went by the book today and the garage actually his 30 degrees with heavy sunshine and calm winds today. Went from 11 to 4. head cover, head, and block are off and partially cleaned. They pieces would really have to be blasted to get any decent paint job on them. Not sure what to do there. Improvised a flywheel holder with a rubber truck bungee wrapped around it and clamped to the lift. Given just 51 ft lbs I was able to pop the nut easy enough. The secondary shaft is easy to get out, but it sucks to put back in, need to pull a pressed gear, reset a bearing in the case and then put the gear back on after the shaft is in the case. I do not yet have all the seals from partzilla and Z1 yet. Also ordered the special oil galley orings in the pan as I didn't have those in the gasket set. I have about 50 bags of hardware labeled and waiting.After the spit I'll wait for some warmer weather for polishing covers on my bench wheel.

I pulled the valves out.Seating looks fine, but some rust on the exhaust valves. Not sure how to clean stem just below the valve, there is some built up crud. One intake valve was a bit sticky. Will clean more and asseembly lube when going back together for lapping should end that issue. Overall things are going well. So glad I got the stand, it made the jobe a lot easier. I will video full reassembly, it's been a tad cold to produce a video. :lol:

Any tips on gear removal on the secondary shaft or valve lapping cleaning I'd appreciate it.

A few pics.

R

Some pics.

a few more.