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KZ650 cafe-racer 17 Sep 2021 02:07 #855388

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Nice work Gazzz, you have the cleanest workshop I have ever seen....!!!!
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KZ650 cafe-racer 17 Sep 2021 05:09 #855392

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I admire your restraint - if I was at that stage I'd be up until 2 A.M. finishing the engine. Beautiful work!
1982 KZ750 Spectre - Dyna 2.2 coils + 8mm wires, WG coil relay, SH775 R/R, Mikuni BS34s - 40P/122.5M, Progressive fork springs/KZ900 rear shocks, Vance & Hines 4-1

2001 ZX-6R
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KZ650 cafe-racer 17 Sep 2021 05:17 #855393

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Absolutely beautiful assembly and pics. extremely righteous
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KZ650 cafe-racer 17 Sep 2021 14:03 #855414

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Thanks!
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com

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KZ650 cafe-racer 17 Sep 2021 14:20 #855415

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With pistons in place and rings gaps aligned according to Wiseco recommendations it was time to prepare things for cylinder installation. First came brand new (Liska Racing) lower idler roller, new genuine roller shaft and damper rubbers.


 


I don't see where you put o-rings on studs. I am sure you did, just didn't see it documented.

And that bearing on liska roller has some surface rust. Are you sure it's OK? 

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KZ650 cafe-racer 18 Sep 2021 00:07 #855432

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It's definitely not rust. It looks rather like heat treating (goldish brown colour) and it was like that from the start, see photos attached. I've checked, it's not an unusual finish for Koyo needle bearings that were made in Germany. 

As for the studs O-rings, you definitely have seen my post about them, because that post already bears your like: www.kzrider.com/forum/11-projects/610746...cer?start=408#850596
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 18 Sep 2021 05:44 #855435

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As for the studs O-rings, you definitely have seen my post about them, because that post already bears your like: www.kzrider.com/forum/11-projects/610746...cer?start=408#850596


I forgot those stud O-rings when building my 750 engine.  Fingers crossed they are not critical...

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KZ650 cafe-racer 18 Sep 2021 06:20 #855437

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It's definitely not rust. It looks rather like heat treating (goldish brown colour) and it was like that from the start, see photos attached. I've checked, it's not an unusual finish for Koyo needle bearings that were made in Germany. 

As for the studs O-rings, you definitely have seen my post about them, because that post already bears your like: www.kzrider.com/forum/11-projects/610746...cer?start=408#850596

yes, I forgot I figured you would do it right before putting cylinders on.

as far as rust goes - that was a joke :)

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KZ650 cafe-racer 18 Sep 2021 13:21 #855454

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I forgot those stud O-rings when building my 750 engine.  Fingers crossed they are not critical...




From two holes for studs that have to be equipped with O-ring only one (front) is not blind.  With crankcase ventilation working correctly there is no pressure as such in the engine case.So all you are facing is the theoretical possibility of oil sweating through the stud thread. With the stud tightened, the non-threaded part (boss) of the stud  closes the hole pretty tight. O-ring just makes the system completely bullet proof. When I was removing the studs, the stud with O-ring and non-blind hole was as hard to remove as any other, so  I could assume that no oil sweating happened to it.
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com

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KZ650 cafe-racer 30 Sep 2021 13:44 #855968

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With the cylinder head in place my next tasks were camshafts installation and timing adjustment. I bought a Kawasaki Zephyr 750 camshafts for the KZ650 project. They are mostly identical to KZ750 camshafts and have similar lobe heights but Zephyr 750 exhaust camshaft has only blank in place where KZ750 has tachometer gear. Therefore, Zephyr 750 camshafts are still compatible with KZ650 cylinder head and camshaft sprockets.

Photos of me  working was taken, as usually, by Oksana. 



All-new components of new upper idler assembly: 



PMC manual tensioner. 

Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 30 Sep 2021 13:46 #855969

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As for the valve shims, I started with the thinnest on the first camshafts installation and then, after measuring gaps I replaced them with shims of correct values. 





As for the timing adjustment, well,  it’d be better to put it in a separate article (and pictures for it are already ready). 

Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 30 Sep 2021 13:48 #855971

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Therefore, let’s jump to the  transmission cover. And again, all components except the cover itself and neutral switch were new. 



I didn’t use the shift shaft oil seal guide for cover installation. Instead I checked the shaft for smoothness and put the cover slowly with seal and shaft oiled. 

 

Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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