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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 15 Jan 2023 05:47 #878842

  • wdhewson
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I'll see if I can upload the video of spinning up the speedo with a square tipped bit in my drill.
Nothing quite like the rip of a Big KZ
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 15 Jan 2023 07:44 #878843

  • Mikaw
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They are the correct gauges as mentioned. The problem is the retaining ring, factory would be a one piece stainless steel that is crimped in place. The split bolt type someone swapped in will not be water tight. Fogging on the bezel lens might be an issue at minimum.  I’m trying to remember but I think there is a gasket the fits between the inner and outer upper shell and seals against the lower shell. I didn’t see that in your photos. 

z-fever for one sells them. z-fever.de/shop/en/shopping_cart.php
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 15 Jan 2023 07:51 #878844

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Looks like you need to visit Vintage Connections and get some items to fix the hacked up wiring. They sell great starter kits at a reasonable price. They also have the vinyl sleeves to replace what you cut off. Also go to evilbay and get a set of connector terminal release tools

vintageconnections.com/

 
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 15 Jan 2023 10:29 #878852

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Thanks guys,

I don't recall an instrument bezel gasket for either the speedo or tacho.  Despite all the weather tools we now have, I do get caught in a rain ride about twice a year.  I might "paint" a thin layer of non-hardening sealant at that joint under the ring.

The de-pinning tool looks excellent.  My skill and luck with de-pinning is abysmal.  Re-wiring this bike will be a chore, as it seems to have been "insensitively" disassembled regarding wiring and the PO was very honest about this.  My goal is a simplified wiring with a quality emphasis on the ignition circuitry.  

Next I'll do a little work with the output sprocket and clutch throwout mechanism.  I think the inner cable is rusted to the outer cable, as the lever has no travel and hits a hard stop.
Nothing quite like the rip of a Big KZ
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 15 Jan 2023 14:45 #878860

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After 40+ years of a stiff clutch I switched to a late model clutch setup. No more binding worm drive plastic POS. I also broke down and bought a needle bearing pusher for inside the clutch basket. The bike now has the pull of a 350 and no more clutch drag. 
I suspect that's what was causing the 2nd gear shift dogs wearing out. 
All good now. 
Steve
 
1977 KAWASAKI KZ650 (#364) CLUTCH ACTUATOR SHAFT PUSH LEVER AXLE
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 16 Jan 2023 08:33 #878877

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Thanks guys.

It looks like I do have the updated clutch pressure plate lift mechanism with the helical ramp ball bearings.  Disassembled it, cleaned the bits, and reassembled it with some nice smooth grease.  Can't say I've ever serviced or seen a helical liner ball bearing assembly before.

Cleaned up the front sprocket a bit, and it's a 17T 530 for sure, and with the 41T rear is a bit higher ratio than I'd like.  So maybe a 37 or 38T rear.  The washer looks like it has a tab to bend over, but I cannot tell where this tab would locate.  See green arrow.

And the headstock VIN sticker is as clean as it'll get.  Some cable friction has damaged it.

More later.......helps Winter to pass by.
Nothing quite like the rip of a Big KZ
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 16 Jan 2023 08:57 #878878

  • Kelly E
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The tab on the washer is supposed to be bent at 90° and the correct sprocket has a small hole close to the center splines that it fits into. That sprocket looks like a Honda part with the two threaded holes on each side of the splined hole.
The Rust Bros. Garage Collection
1974 Honda CB550 K0
1975 Honda CB400F Super Sport
1977 Kawasaki KZ1000 LTD
1979 Honda CB750F Super Sport
1980 Suzuki GS1100E
1982 Honda CB900F Super Sport
1983 Honda CB1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
And more

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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 16 Jan 2023 13:30 #878890

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Thanks for the tab washer information. 

Maybe I'll make a soft steel washer with bolt holes for those "Honda holes", then fold up the washer against at least one of the nut's flats.

In addition to some Loctite.

Perhaps that starter motor would benefit from removal and service.  I'll have to vacuum out the extensive spider colony to have a better look.

 
Nothing quite like the rip of a Big KZ
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 17 Jan 2023 13:10 #878918

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South wind brought some warmth to the unheaterd garage, so I did a little more dismantling.

Needed to remove the rear mounted cam chain tensioner to get the starter motor out.

And I pulled the points plate and mechanical ignition advance.

That'll give me some indoor work for several days.

Please do comment on what you see in the pictures, along with any type of advice or updates.

Thanks.



 
Nothing quite like the rip of a Big KZ
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 18 Jan 2023 02:00 #878935

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Hi, Disassemble your starter motor, clean everything and check the carbon brushes!
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 18 Jan 2023 07:52 #878942

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Hi, Disassemble your starter motor, clean everything and check the carbon brushes!
Good preventive maintenance advice. Please mark the aluminum end caps and the steel body to assure correct “clocking” upon assembly. Also the armature shaft has very thin shims, take care to note placement, again to assure correct assembly. 
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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Trying to Rescue a Late 1970s (1977??) Kawasaki KZ1000 18 Jan 2023 08:14 #878943

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You are doing this bike justice. Thank you Sir. I have been watching in the background because my first Kawasaki was a 1977 KZ1000 way back in the early eighties. 
Don't be ridiculous! It's only a flesh wound!

Wife's little bike... 1984 GPZ 550 Kerker and DynaJet stage I kit
Wife's BIG bike...... 1981 GPZ 1100 Kerker and factory FI Mikuni RS34s W/ K&N pods
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