How to dry block your kz900/1000.

Hey I was just curious, how did you plug the oil galleries in the cylinder head? Do you have any good pictures of the cylinder head showing this, that you could post? I am wanting to do this on my bike because I have a big street motor (1327cc). They are a pain to get them to seal, that's for sure.

Awesome post - thanks for sharing! I might do this the next time I have mine apart since my cases are bored.

Very, very nice work too!

School Teacher wrote:
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Good idea!

Also do you do this to both sides of the head? If so i don't see the line going to the other side.[/quote]

Yes it must be done on both sides. The splitter block i made has the two right hand lines fitted on top of the block and the left hand ones underneath which can be seen in the bottom right of this pic looping round the starter motor housing

mkawasaki23 wrote:

Hey I was just curious, how did you plug the oil galleries in the cylinder head? Do you have any good pictures of the cylinder head showing this, that you could post? I am wanting to do this on my bike because I have a big street motor (1327cc). They are a pain to get them to seal, that's for sure.

Hi. The oil galleries in the head are also 6mm which i drilled 6.8mm and tapped m8 then used easily removable grub screws loctited in to blank them off, although as previously mentioned interference fit alloy bungs could be used similar to kawasaki's method but these would have to be drilled out if the oiling system were to be reverted back to std at a later date.

could u just use brake lines and banjo bolts? would they be the right size?
Your work looks very pro.

mark1122 wrote:

could u just use brake lines and banjo bolts? would they be the right size?
Your work looks very pro.

Don't think brake lines would flow enough oil ? I wouldn't try it. It could be an expensive cheapskate experiment in the long run if you get oil starvation,Destroyed cams and shells at the very least . I went for Dash 4 lines as they have a 5mm bore that is more or less the same dia as the original oil gallerys and have run my bikes on the same set up for the last ten years with success.

Very Good point .
Thanks.

I really like the brake line idea because of its simplicity and availability of parts. The SS braided lines would look great and the ports could be tapped to fit the standard banjo bolts. Very simple installation compared to making your own banjo fittings or if your not familiar with AN fittings and all of that stuff.

I guess we'd have to find out the flow requirements and see if the brakeline ID is large enough. As mentioned, that would be a very expensive experiment, but I really like the idea if the lines flow enough oil. Maybe a fluid dynamics expert can chime in on flow, diameter, pressure, etc...

Does anyone know the ID available for brakeline that fits our standard banjo bolts?

A great mod and one I plan to do on my 904cc 750. The restrictors on the 750 are only 3mm approx so -3 brake line size hose would do fine and would be lighter too.

Lorcan wrote:

A great mod and one I plan to do on my 904cc 750. The restrictors on the 750 are only 3mm approx so -3 brake line size hose would do fine and would be lighter too.

Brake line should be fine on the 650/750 motors as they run shell bearing cranks and hence high pressure pumps.The restrictors are there to keep the pressure up for the crank. The 900/1000 etc are roller bearing and run lower oil pressure hence the need for higher volume oil lines.

I am still VERY interested in having this done to my head this fall. Does anyone know of a person that can do this work in the States?

I checked with Ward Performance about their top end oiler kits that they sell for the Suzuki's and for the Vortex heads and they told me that the stock Kaw head casting is too thin to run a top end oiler kit. I was really hoping they would at least do the machining if not sell a whole kit too. I think the castings are plenty thick since we have people on here that have done it and tested it for years with no issues.

that really is awesome work btw are kzs popular in jolly old england ?? old trumpets(triumphs) & beezas(bsa)& nortons are well respected here in the states!!!!! also would one NEED an oil cooler with your setup ???