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Rebuild of KZ1000J engine 02 Aug 2022 17:23 #871554

  • Dr. Gamma
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You are correct, lazy US machanics always use impact guns, who cares what´s next......
 

Actually one of the first "mechanics" I saw and heard crack a Z1 case was this German fellow we hired for the summer rush Waldameer Otto Paul was his name. WHAT A HACK!!!!!
He spent more time fixing his comebacks than he did booking hours!!!! His own personal bike ran on three of its four cylinders most of the time!!!!
1972 H2 750 Cafe Racer built in 1974.
1976 KH400 Production Road Racer.
1979 Kz1000 MK. II Old AMA/WERA Superbike.
1986 RG500G 2 stroke terror.
1986 GSXR750RG The one with the clutch that rattles!

Up in the hills near Prescott, Az.

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Rebuild of KZ1000J engine 02 Aug 2022 18:59 #871559

  • TexasKZ
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1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Rebuild of KZ1000J engine 02 Aug 2022 19:07 #871560

  • Scirocco
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Sorry Doc if i blame the reputation of the US mechanics but some YT channel mechanics first choise of tool to loosen and fasten nuts and bolts is an impact gun or air driven ratched! Mea culpa! Some raw handeling "mechanics" shouldn´t alout to touch any tools like this.....

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Last edit: by Scirocco.

Rebuild of KZ1000J engine 02 Aug 2022 19:43 #871565

  • Street Fighter LTD
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You said U Tube    I hate U tube experts..  
A lot of them are real hacks  no matter where they are from .
 Some good info can be had , but you need to cut thru the bull to find that one real good guy who can be of real help
NO Impacts for my Kaw

Original owner 78 1000 LTD
Mr Turbo Race Kit, MTC 1075 Turbo pistons by PitStop Performance , Falicon Ultra Lite Super Crank, APE everything. Les Holt @ PDM's Billet Goodies . Frame by Chuck Kurzawa @ Logghe Chassis . Deep sump 5qt oil pan. RIP Bill Hahn

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Rebuild of KZ1000J engine 02 Aug 2022 19:59 #871566

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Sorry Doc if i blame the reputation of the US mechanics but some YT channel mechanics first choise of tool to loosen and fasten nuts and bolts is an impact gun or air driven ratched! Mea culpa! Some raw handeling "mechanics" shouldn´t alout to touch any tools like this.....
 
I have seen real good flat rate mechanics use air tools for disassembly without any problems. But never use them for assembly!!!
Most YouTube "mechanics" are great for a good laugh!!!! I love the ones with the gallon tubes of Red or Blue Silicone sealant. You can see the huge beads of it on every gasket area!!!  
1972 H2 750 Cafe Racer built in 1974.
1976 KH400 Production Road Racer.
1979 Kz1000 MK. II Old AMA/WERA Superbike.
1986 RG500G 2 stroke terror.
1986 GSXR750RG The one with the clutch that rattles!

Up in the hills near Prescott, Az.

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Rebuild of KZ1000J engine 02 Aug 2022 20:04 #871568

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You said U Tube    I hate U tube experts..  
A lot of them are real hacks  no matter where they are from .
 Some good info can be had , but you need to cut thru the bull to find that one real good guy who can be of real help
NO Impacts for my Kaw
 

The only place I use an impact wrench on my Kz is to tighten the clutch nut and counter sprocket nut. And never more than  one or two quick bursts on the nut!!!

Never had a clutch or counter sprocket nut come loose since 1972!!!!
1972 H2 750 Cafe Racer built in 1974.
1976 KH400 Production Road Racer.
1979 Kz1000 MK. II Old AMA/WERA Superbike.
1986 RG500G 2 stroke terror.
1986 GSXR750RG The one with the clutch that rattles!

Up in the hills near Prescott, Az.
The following user(s) said Thank You: Street Fighter LTD, Scirocco

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Rebuild of KZ1000J engine 02 Aug 2022 22:35 #871572

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Sorry Doc if i blame the reputation of the US mechanics but some YT channel mechanics first choise of tool to loosen and fasten nuts and bolts is an impact gun or air driven ratched! Mea culpa! Some raw handeling "mechanics" shouldn´t alout to touch any tools like this.....

 
I have seen real good flat rate mechanics use air tools for disassembly without any problems. But never use them for assembly!!!
Most YouTube "mechanics" are great for a good laugh!!!! I love the ones with the gallon tubes of Red or Blue Silicone sealant. You can see the huge beads of it on every gasket area!!!  
When I spannered for a living my air tools paid my mortgage (time was money) but there is a time and a place 
1982 KZ1000 Ltd
The following user(s) said Thank You: Nessism

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Rebuild of KZ1000J engine 03 Aug 2022 04:17 #871575

  • Jonas_Z1000j
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The cases and faring looking great on your z900!!!
 
Thanks! I kinda like the look of  "universal bikes" with some touring stuff on them. Looks like adventure to me
Z1000 J2 -82 not so running restoration object anymore
Z900RS -21 Green/Yellow

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Rebuild of KZ1000J engine 03 Aug 2022 04:28 #871576

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I checked the factory service manual (downloaded here) for the J-bikes and it makes no mention of 3 m8 holes for the split?

 

It also says to use the pry points? was the 3 m8 holes removed on J?

Here is a picture of the lower case if someone can find the holes to split it:



Im a big fan of removing fasteners with the impact wrench, but I dont use it to tighten smaller bolts. I did tighten the alternator bolt with it last time, and that worked and saved me some hassle!
Z1000 J2 -82 not so running restoration object anymore
Z900RS -21 Green/Yellow
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Last edit: by Jonas_Z1000j.

Rebuild of KZ1000J engine 03 Aug 2022 06:20 #871581

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I checked my GPZ FSM and it had the same crankcase splitting instructions that you posted.  The crankcases did change,( rubber engine mounts) I didn't remember them doing away with the jacking holes, but they should be fairly obvious if they are there. Maybe too many cases got broken using the threaded holes incorrectly? I was taking inventory yesterday of parts to reassemble a 1976 motor and it has 17 lower case bolts. There are pry points cast into the case, but I always used them as little as possible, a large plastic dead blow hammer was my crankcase splitting friend. As far as assembly with impact tools, air in the past, cordless electric now, future ?, I can guarantee you that power tools are used on the engine assembly line with a great deal of skill.  Like any other tool it takes practice, fasteners are tightened to below the torque spec. with the power tool and then finalized with a hand torque wrench. (which can also be used incorrectly!) I worked along side Japanese Engine Line workers on several projects and they were machines!  

Mike

 
Former M.E. at Kawasaki Motors Manufacturing, Lincoln, NE
1966 W1 (the Z1 of 1966-50H.P. and 100mph!)
1974 Z1A (disassembled)
1976 KZ900B LTD (SOLD!) it's in GOOD Hands!
1978 KZ1000 LTD
1976 KZ900B pile O parts
1980 KZ750E
1980 Honda XL250S (I know, wrong flavor!)

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Rebuild of KZ1000J engine 03 Aug 2022 06:34 #871584

  • TexasKZ
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The Z/KZ engines have that provision, but the J engines do not.

I posted the link to the earlier engine, assuming that is what he has, but upon closer inspection, it seems he has the later J engine which has pry points.

I apologize for adding to the confusion.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Last edit: by TexasKZ.

Rebuild of KZ1000J engine 03 Aug 2022 09:28 #871604

  • Jonas_Z1000j
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Just got it open! Did not take much force with the pry method, im surprised
Next couple of days will be gasket removal (have not come across any magical way of removing them even though I have googled it for days probably) and cleaning of the cases.

Have found a source for a lot of parts in Germany, they have the original Morse camchain, guides etc that I will order. Plan is to get the crank case back together as soon as possible. 


 
Z1000 J2 -82 not so running restoration object anymore
Z900RS -21 Green/Yellow
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