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TOPIC: 83 KZ1100ltd Rebuild

83 KZ1100ltd Rebuild 15 Feb 2019 11:47 #798724

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Thanks for the responses/suggestions. I think a machine shop is in the future for those cases. Luckily only one bolt broke.

I cut a slit in the bolt to use a flat head impact driver on it, soaked it in liquid wrench, and put heat to the case. After some persistence, I only succeeded to brake the flat head bit and brake off one side of the cut bolt. :angry:

As a last desperate act I attempted to weld a nut to what was left of the stud but the only thing worse than the cheap MIG welder my buddy has are my welding skills. The weld failed with only minor torque. Luckily I didn't damage the matting surface. Covered everything with adhesive foil tape.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd

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83 KZ1100ltd Rebuild 15 Feb 2019 11:57 #798725

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I've got the spare set of cases cleaned up and removed all the old gaskets. I've been waiting on some parts to reassemble the cases but I've got the crank and transmission in place.


Make sure you remember to put the cam chain on the crank before positioning the crank, because I didn't.


There are a series of pins on the main bearing surface. Each roller on the crank has a hole you have to align with the pins. Otherwise the crank won't sit right.


I had to rotate and slide the bearings quite a bit to get them all aligned.

After the crank was seated I dry fit the cases. Seemed to fit.


The service manual indicates you can assemble the cases with the shifter forks in place. It's one more thing to track when mating the cases but it seems doable.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd
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83 KZ1100ltd Rebuild 15 Feb 2019 16:34 #798744

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I agree with the last few posts, Streetfighter about see if others break, and specifically Matt's about threading a nut on and weld it to the stud on the inside. But first I'd soak it for days in penetrating oil. Once the nut is welded on after soaking, hit it with an impact gun/socket.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
06 ZG1000 Concours
02 Trans Am ... not enough time

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83 KZ1100ltd Rebuild 17 Feb 2019 17:59 #798837

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Mailman came through with the parts on Friday! Got everything required to put the engine back together, well at least as far as the parts are concerned.

Cleaned the case matting surfaces with acetone one more time and applied a modest coating of yamabond to the upper case. I've gotten to where I like to apply the sealer with the transmission out, in order to get to the surfaces between the bearings. After the sealer is on, I refit the transmission. I've the found the time it takes to fit the trans is a good proxy for the yamabond setup time.

It's a little late but does anyone know if there's a temp range for applying yamabond? It's been colder here in KC and I'm not sure if it's too cold. Or if there even is a too cold. The sealer seemed fine and went on like normal so I'm hoping everything's peachy.

Got the case haves all torqued down and didn't see too much sealer squish out so hopefully I got the right amount applied. The crank spins smoothly and the transmission shifts through all the gears.

More to come in the next post.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd

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83 KZ1100ltd Rebuild 17 Feb 2019 18:11 #798838

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Fit the oil pump next. The manual says to prime the pump by filling it with oil but a good bit of the priming oil seems to have wound up on the floor. Is that typical?

Popped on a new oil pan gasket and o-ring along with a new oil filter and the original drain plug and the bottom's all buttoned up.

I've read that greasing the gaskets can help. Has anyone heard or practiced this? I rub the grease into the gaskets, if nothing else it seems to help them stick in place on the engine when I'm installing the covers.

Flipped the engine over and installed the shifter mechanism and greased up bevel drive gears. The clutch went on simply enough. The existing plates and springs looked good so I reused everything.

The starter motor, gears, and clutch also went on without much issue. Everything torqued to spec.

More to come.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd

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83 KZ1100ltd Rebuild 17 Feb 2019 18:28 #798840

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I had been spending some time over the last few weeks cleaning and polishing the engine covers. The covers which came with the bike have some damage but I'm going to use them anyway. I've got 'em looking decent and I don't mind the look of covers with a bit-o-damage. Makes it look like the bike was well used and well loved.

All the covers, save the small round ignition cover, are back on the engine. Need to access the crank bolt to spin the crank so no sense in installing the cover only to have to take it off again.

Next I put the pistons back on. The piston pins looked a bit worn so I ordered new ones.


Always make sure the openings to the engine are covered to prevent parts from falling into the assembled engine.


A little engine assembly grease on the pins and everything slid into place. Installed new snap rings and only had one ring pop off and fly away. Small victories!

The rings and cylinders looked good so I'm going to reuse the rings and leave the cylinders as they are. Only cleaned some buildup from the top of the pistons.

Next to the cylinder head studs. I cleaned up the threads of the studs and chased the case threads, M10x1.5 for reference. The studs threaded in by hand just fine. Should I attempt to torque them down, like a reverse double nut method? Or just leave them hand tight?

Now I need to clean up the old gasket from the bottom of the cylinder and it'll go on next.

Thanks for reading so far.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd
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83 KZ1100ltd Rebuild 17 Feb 2019 18:56 #798842

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I've never done head studs before, but I don't think it should matter. When you tighten down the head nuts it should turn the studs as well if they aren't bottomed out, just whatever is loosest.
83 KZ1100A (shaft)
17 Versys X 300 abs
90 Honda CBR600F (brother's)

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83 KZ1100ltd Rebuild 17 Feb 2019 19:00 #798843

  • SWest
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Tighten them down good and snug.
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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83 KZ1100ltd Rebuild 17 Feb 2019 19:06 #798844

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SWest wrote: Tighten them down good and snug.
Steve


Double nut method work? Have a recommended torque or just feel it?
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd

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83 KZ1100ltd Rebuild 17 Feb 2019 20:11 #798846

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Tight enough so they won't back out when you take the head nuts off.
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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83 KZ1100ltd Rebuild 23 Feb 2019 10:23 #799100

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This is what relief looks like...


While installing new piston clips to replace the clips removed during disassembly, one of the clips flew out and I couldn't tell where it landed. Fearing the worst, I spent a fair bit of time searching for the part around the crank and inside the engine.

Very close to deciding to remove the oil pan I walked away from the problem to take care of some housekeeping around the garage. I needed to pour out old oil from a drain pan in order to make room for when I get the frame back.

Imagine my relief when the outline of a clip started to become visible in the oil drain pan. Thank God I didn't have to tear into the just assembled engine.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd
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The following user(s) said Thank You: Street Fighter LTD, SWest, gordone, M_a_t_t

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83 KZ1100ltd Rebuild 09 Mar 2019 07:24 #799983

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After a bit of a delay, the powder coater came through and everything looks great.

Set off straight away after work yesterday and installed the new swing arm bearings from All Balls.



Packed the rollers full of grease and pushed the seals into place. Next to install the pivots. Had a bit of overspray in the holes which required some dremel work to remove but they went in easy enough.



Positioned the swing arm and installed the center stand. Then it was time to call it a night.



Popped the stearing bearing races into the freezer before dinner. Will get back to the build after MotoGP qualifying is done this morning.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd
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83 KZ1100ltd Rebuild 09 Mar 2019 08:13 #799991

  • ajsfirehawk
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Looking really good. I too have an 83 KZ1100 LTD and I love the way it rides. I ride quickly but rarely aggressively and it is just a ball. Watching your progress with interest.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
06 ZG1000 Concours
02 Trans Am ... not enough time

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83 KZ1100ltd Rebuild 09 Mar 2019 19:40 #800037

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Good progress today. Got the front end installed with new stearing bearings and fork seals, slid the motor in the frame (with help), assembled some of the battery box and popped that in (less of a struggle with empty frame), and removed the valves from the head for cleaning.

The neck bearings went in okay but the stem roller was less straightforward. How to press the inner race onto the stem?



On advice from a post, I kept the old inner race and tapped on it with a punch and a hammer. Working one side down a couple taps then moving to the other.



Then packed it with grease and installed the stearing neck.

More to come...
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd
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83 KZ1100ltd Rebuild 09 Mar 2019 19:47 #800038

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I've got the wheels on for stability when installing the engine. They are coming back off to be cleaned and for new wheel bearings.

I wanted to protect the new finish so I wrapped the frame with bubble wrap and laid a towel down.



Moving the engine is a two man lift for me. Called a buddy and he helped get the motor in the frame. Took some wiggling and the use of a motorcycle jack but got the motor mount bolts in place.



More to come...
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd
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83 KZ1100ltd Rebuild 09 Mar 2019 20:01 #800040

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With the motor in the frame the head can be installed...after I disassemble, clean, and reassemble it. Wanted to capture the disassembly process incase it'll be useful for someone.

Working on a towel gather the head, spring compressor, old egg carton, a sharpy pen, and a magnet or two would be useful.



Use the marker to number the valve tappets and transcribe those numbers onto the egg carton. This helps ensure everything goes back where it came from.




Use the spring compressor to...well compress the springs. When the keepers are loose, use a small magnet to remove them from the valve stem.



Loosen the spring compressor and remove the top retainer and both springs. Keep track of the spring orientation. Push out the valve, slip on the springs, retainer, and keepers.

Rinse and repeat for the rest of the valves.

1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd

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83 KZ1100ltd Rebuild 09 Mar 2019 22:15 #800045

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Enjoy following!
Keep up the good work you doing!
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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83 KZ1100ltd Rebuild 17 Mar 2019 17:52 #800515

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I've been neglegent in documenting the progress of the rebuild so the images are mostly of completed steps.

Good progress on the Ltd this weekend. Got most of the mechanical and electrical parts at least positioned. Got the master cylinders disassembled, cleaned, rebuilt, and reassembled. Mounted the handlebars, levers, and controls. Lubricated and mounted the clutch cable, seems to work smoothly.




Also had a chance to clean up the front wheel, replace the wheel bearings, and repack the spedo drive gear.



The calipers will come back off for cleaning and maybe rebuilding. The rear wheel is also coming back off for cleaning and for new bearings.

Still need to hook the stand springs but the stands are in place.

A lot of what's left is electrical :sick:

I'm sure I'm going to have some issues with the spliced main harness. The Vetter fairings and bags required cutting into the harness and I suspect the wiring diagrams in the service manual will no longer be totally useful. So if/when issues arise I'm going to be spending a lot of time chasing connecting with a multimeter.

Oh well, that's a problem for future me. Man I don't envy that guy.
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd
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83 KZ1100ltd Rebuild 07 Apr 2019 13:45 #801725

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I stripped the factory Vetter fairing, bags, trunk, even the KHI floor boards and forward controls off of my 83 KZ1100 LTD and rain into a good bit of what you are talking about with the wiring harness. One 12 inch section in the rear had 4 splices with three different colors of wire. BUT...the factory manual did help a bunch. When you buzz it out, hooking up your meter at the right color wire on a connector, then connecting to the different non- stock wires until you get continuity will help you. Immensely. You can get there, I'm no wizard and I did. She is looking good.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
06 ZG1000 Concours
02 Trans Am ... not enough time

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83 KZ1100ltd Rebuild 21 Apr 2019 17:49 #802583

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Sorry for the lack of activity on this thread, quite a bit of changes coming in my life. I am going to have to halt work on everything soon for a long while, couple years anyway.

When I have time to work on the bike I've failed to document the progress but the air box and carbs are back on along with the cables, controls, and grips. I don't think I'll get it ready to fire before I'll have to stop work and store it. Might be able to get a battery in and check for spark and all that.

Looks like this beauty is going back in hibernation but she'll get back on the road eventually. ;)
1981 Kawasaki KZ1100A1
2018 Triumph Rocket 3
1977 Yamaha RD400
1980 Honda Express II
1983 KZ1100ltd

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