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TOPIC: Saving a '81 KZ750-E

Saving a '81 KZ750-E 07 Jun 2019 10:17 #805307

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Finally correcting my mistakes. Three inches wider near the swingarm pivot, and one and a half inches farther away from the pivot. Chain and frame clearances look much better.
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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 07 Jun 2019 10:49 #805308

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Last tubes fitted.
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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 11 Aug 2019 14:07 #809043

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Been really distracted last couple of months, so haven't had much progress. Today I finally got some time to do the first mock up of the suspension. Seeing the wheels on the frame is oddly motivating! The frame, swing arm, and kickstand will be headed to blast and powdercoat soon. Really happy to have moved into my new shop!
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'81 KZ-750 E1
'86 Suzuki Savage 650
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Last edit: by Skidmark.

Saving a '81 KZ750-E 15 Sep 2019 11:32 #810882

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I had a real hard time getting the swing arm pivot bearings out. When trying to drive them out with a punch, the inner cages got destroyed on one side, leaving an even smaller edge to catch. I was able to get one side out, but for the other side I ended up purchasing a steel round bar, 1-1/16" in diameter, to press the outter races out. Good plan on paper, but the bearing bores were not machined on center of the tube. Even though the bar was smaller than the bearing bore, it would not go through with out using my 20 ton shop press. I finally succeeded, and with some more dressing down the swing arm will be ready for powder coat. The inner sleeve is worn beyond use, but I found All Balls Racing sells a sleeve almost the same size. It is .002" larger on the OD, so I may need to have it precision ground. Anyone know where to get an original stock sleeve?
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'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 15 Sep 2019 12:47 #810889

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Do you have the dimensions of the sleeve you need OD/ID/length in metric mm?
Your needle bearing typ is Hk2216 = OD 28 mm, ID = 22 mm, length = 16 mm (you need 2 needle bearings on each side).

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Saving a '81 KZ750-E 15 Sep 2019 14:03 #810892

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The same sleeve was used on the later 650's but unfortunately, it's been discontinued by Kawasaki and ebay doesn't have anything.

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Saving a '81 KZ750-E 15 Sep 2019 14:32 #810894

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With some work on the lathe you can repair your worn part of the sleeve with following parts.

www.kugellager-express.de/drawn-cup-need...2216-2rs-22x28x16-mm



www.kugellager-express.de/inner-ring-ir17x22x16-17x22x16-mm

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Saving a '81 KZ750-E 15 Sep 2019 18:33 #810904

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The stock sleeve OD measures 21.94 mm at a spot without bearing contact. With a 22 mm OD sleeve, I would need to have it ground to fit in the stock bearings.
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'81 KZ-750 E1
'86 Suzuki Savage 650

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Last edit: by Skidmark.

Saving a '81 KZ750-E 04 Oct 2019 14:29 #811803

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Finally got my blast cabinet up and running. I am using 80 grit glass bead for the media. The swing arm came out really nice! I have a long list of parts that need blasting, so I am realy glad I have this piece of equipment in my shop!
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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 04 Oct 2019 15:06 #811804

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Factory Kawasaki weld... WTF?
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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 04 Oct 2019 15:29 #811806

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Looks like the welder run out of protective gas.....

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Saving a '81 KZ750-E 04 Oct 2019 19:47 #811826

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Exactly. Fix it? Nah, just send it down the production line...
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'81 KZ-750 E1
'86 Suzuki Savage 650

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