KZ1000 troubleshooting tear-down

HISTORY:
So, this bike had unknown issue/s since it was built by some friends from boxes of parts about 10 years ago. It has a Dyna III, Dyna coils, and WG's BS34 conversion. Until today, we didn't know if it had a big bore kit, though we suspected it. It has a nasty noise when it is running that, with my mech's stethoscope, I narrowed down to being the loudest near the underside of the tranny, closer to the clutch housing. The bike starts up nice and seems to run good, but on test runs it does not perform anywhere near what it should.

FIRST QUESTIONS:
So, today we discovered Wisco high comp piston that have H46D0 stamped on the tops. We think they are the 1075 kit. The other thing we noted was that when you spin the rear wheel, the chain will go from very slack to very tight...? This is the first real issue we have found and are wondering what would/could cause it?

Sounds like the chain is bad. Get a new chain and sprockets and the problem will be solved.

seems like some one here had a bad bushing in the clutch basket, you might search the buy kawi site for a break down

Post edited by: BSKZ650, at: 2007/11/22 08:27

Heres my best guess.
(1) A badly worn chain+sprocks.
Will make some very nasty noises..

(2) A broken clutch basket SPRING.
Will also make the same noises and you can feel
it when you are riding, in the foot pegs.

Last but not lest
Who ever built the motor may have installed
a Welded clutch basket.

Know way of knowing till you take the clutch apart
and look.

sometimes clutches clunk when the clutch is out in neutral, if the actutator rod is not properly adjusted,