KZ1000A1 Spare Parts Project

And sorted! it all looks newer than new, great work.

Looks stunning, and I bet that roll pin is stronger than the original 

This it turning in one super nice “spare parts” bike. Not your average spares. 

Thanks guys. May have gone a bit overboard with the spares  

Picked up the cylinder block yesterday. €250 later and it's been resurfaced, blasted and honed for the oversize pistons (70.5mm). 

 

 


I got the second and third fins from the top welded and then filed them down. Turned out alright.

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Nice "save" on the fins 

wrote:

Nice "save" on the fins 

Hi Calum,    I have a friend that fixes/welds a lot of fin repairs, he uses a brass block between the fins to make it easier to tig them,  and a heat gun to heat the fins up before welding

I'm missing a single bolt for the oil pan: M6 x 50 with a head as in the picture below. If anyone in europe has one lying around I have a load of other bolts that I don't need.
Would also be curious to know when they went from this head to the flanged head with the 7 stamped in it. A lot of part numbers from the old models point to the newer stamped head. Anyone got any history on this for me?

@750 R1: I'll pass on the brass block idea - thanks.

 


Also would like to get my hands on an M6x22 with the JIS head pictured below. It's for the oil pump so it's not the end of the world if I can't find one.

 

Im 99.9% sure i got you mate, ill just root them out and post them up later on i have about 5 oil pumps around an a bucket of bolts and what not.

Can anyone tell me which of these is the wrong part (if any)? The height of the stator mount in my replica alternator cover is 23mm, the stator is only 22mm high. This means the stator can still move after tightening the three mounting screws. Stator came from a Z1R (probably) and the cover is a good quality replica (from japan?).

 

 

The guy who I got the cover from got back to me. He reckons there was a production error on the cover and it was milled a bit too deep. It's in the post on it's way back to him.

Got some picks from my engine guy. The cracks in the spark plug threads have been welded. He still needs to cut the threads and do the valve seats but he's on holiday now so I can probably pick it up around the end of August.

 

 

Gapped the piston rings today. A lot of filing required - the gaps on the first and second rings were all about 0.1mm too small. One of the rings wouldn't go in and I noticed some damage to one of the pistons that I had missed before. It looks lik it got a bit of a whack at some stage (see the last two photos below). The ring groove was deformed slightly and too tight for the ring. I found a file that was almost exactly the same size as the groove and carefully opened it back up. I'll double-check the groove clearance again but it seemed fine once I got the ring installed. I figure this should be fine on this build.