1976 Kz 900 A4

The engines came to Lincoln fully assembled, but there were times when crankcase sets would need to be replaced and I had the pleasure of totally rebuilding an engine. I always look to see if the engine number looks like one I handstamped on old KZs, would be really cool to see one. In my mind at least the engines I built were done with more care than the ones build on the assembly line in Japan, they DEFINITELY took longer!

Mike

Mike,

We are so lucky to have you as a member with first hand experience with our loved machines. Thank You.

I’ve noticed and always just assumed the numbers were hand stamped. They seem to have Characteristics that would indicate the hand of Man performing that job. It’s been something I look for to authenticate the origanilty of the engine. We’re they though indeed jig stamped?

I never had the opportunity to go to Japan and see the factory, so I can't say how the engine numbers were stamped. I would say on my W1 engines from the 60s they were for sure hand done because they are crooked as hell. I always thought the numbers I had to replicate looked straighter than the one I did by hand, but my skills did improve with practice, as they usually do.

No thanks necessary, I think it's awesome somebody still cares, They are awesome machines!

Mike

krazee1 wrote: I never had the opportunity to go to Japan and see the factory, so I can't say how the engine numbers were stamped. I would say on my W1 engines from the 60s they were for sure hand done because they are crooked as hell. I always thought the numbers I had to replicate looked straighter than the one I did by hand, but my skills did improve with practice, as they usually do.

No thanks necessary, I think it's awesome somebody still cares, They are awesome machines!

Mike

I agree they are awesome. I’m biased as I have never owned another brand. I am amazed that barring the smallest little button. Everything has the capability of being disassembled, serviced and put back into use. Look at the recent restoration slmjim+Z1BEBE just completed.

There are some VERY talented people on in this group Matt, yourself included!

Mike

krazee1 wrote: there were times when crankcase sets would need to be replaced

Can you give some examples of why a set of cases would need to me replaced? These were brand new engines straight from Japan, right?

Maybe damaged in transit? Some problem on the line or a supplier issue discovered after they shipped?

I always look to see if the engine number looks like one I handstamped on old KZs

What years did you build engines? I'm sure we all would be happy to post photos.

hardrockminer wrote: Looks like I was wrong on the loctite. But I've spent hours cleaning grit out of the area between the stud and the hole, and I came to the conclusion that at least some of them had some very hard material placed in there, presumably at the time of installation.

This kind of a statement is what truly shows character. The members have set a great tone and it’s another reason I contribute helping this site continue.

Thanks Mikaw. But don't tell my wife that I was wrong!

Krazee, thanks for that explanation. That's what I thought...I once worked in a major appliance factory where occasionally a unit would have to come off the assembly line and be dismantled because of a defect and then rebuilt by a single person.

I would guess at the time it was mainly a job for you to earn your living and feed your family. Who would have thought back then that those machines would be as sought after today as they are. Today you must have very strong feelings about the work and the people next to you on the floor. I love to read your memories.

DOHC wrote:

krazee1 wrote: there were times when crankcase sets would need to be replaced

Can you give some examples of why a set of cases would need to me replaced? These were brand new engines straight from Japan, right?

Maybe damaged in transit? Some problem on the line or a supplier issue discovered after they shipped?

The engines were probably more likely to be damaged in the Lincoln plant during a fork truck "incident" than during their trip from Japan. They were lifted out of the boxes they traveled in with a jig and a chain hoist, so once in a while one hit the floor. Occasionally we would discover a porous casting or some other casting flaw. I think I still have a crappy Polaroid photo of a GPZ 600 that a connecting rod let go during the dyno test and destroyed the front of the case.

I always look to see if the engine number looks like one I handstamped on old KZs

What years did you build engines? I'm sure we all would be happy to post photos.

I was an Engine Repair Mechanic from 1975 until 2005 when they quit building motorcycles in Lincoln. I think during the 80s there were at least 10 of us in the department, so I didn't do all the engines. Not sure I would recognize my work, I should have made a secret mark! I do have copies of the defect and repair logs that I kept that include Engine and Frame numbers, but I don't think we started keeping track until sometime in the 80s. I really wish I would have kept a diary!

There's an old saying that goes something like "Too soon, too old. Too late, too smart". I think there are a lot of people that wish they would have kept a daily diary of their work experiences after they retired. For some like Krazee it could revolve around what he worked on and repairs that he made plus the changes that went on a the Kawasaki plant and of course good and bad experiences. It would all be quite interesting today that's for sure. A few years after I retired I began to think about my past life job and how interesting it would have been to have recorded them in some way. My wife of 42 years is a Nurse Practitioner in the emergency room of a children's hospital and she has some incredibly interesting stories. I have told her for years she should document her experiences and write a book of what kids go through, but she thinks it might violate HIPPA or some far fetched hospital policy. If you want a real barometer of society all you have to do is watch what comes into a children's emergency room.

I can only imagine what people like Krazee saw and did during his stint at Kawasaki and for me I find his information incredibly useful and interesting. Very much like the people I knew that worked at Harley-Davidson in Milwaukee, or the old AMC plant in Kenosha. Thanks for your insights Krazee!
Rick H.

Another long work day or this would have been in the mail to vapor hone.

Upper and lower cases

Mikaw wrote: They soak for close to a week until my new fav tool arrived. I got a great deal on a craftsman vintage stud puller. Several gave a sharp “CRACK” as the vintage tool over powered them. Others gave in without a fight, like a Lake Erie walleye. I almost bought the 38$ unknown brand from APE until I shopped evilbay and found the craftsman tool. $15 shipped and had it in 3 days. Worked 13 1/2 hour every day this week, quite tuckered. Tomorrow I’ll get them packed up and off to Vapor Hone Saturday.

Now that looks like progress, Matt! Glad to see that those studs came out without too much drama.

Also, a little tip for when you install the new studs (if you're not already aware) -- place a small ball bearing into a head nut and then thread it onto the stud that you want to install. Tighten stud per specs. This beats trying to use a double nut setup. If you look at the top of the factory studs, you'll see a little dimple which implies that the Kawi engine builders used a similar technique. Hope this helps....

Mike