KZ1K'S ENGINE PROJECT

....

....

......

OK, very good. Mwahh ha ha

Do you have an impact gun? If so, its going to get some good use now. If not - get one. It doesnt have to be air, electric will work fine, and cheap is ok too, as you're really not going to use it often at all.

HINT - When using an impact gun, you can assist the gun removing a stubborn bolt by twisting on the socket with your hand. This helps greatly!

Just start taking her apart... I recommend removing the dynamo, clutch basket, etc. and you MUST remove the drive sprocket, shift linkage, etc. before splitting the cases.

Read manual - CONTINUE! :laugh:

Jumping in late on this post but here is what Joe/PSP is doing to my KZ1000-K1.

Kim Smith Estimate 9/28/2010
Qty Description Price Extension
1 Refinish cases, in high temp baked on silver 100.00
1 Refinish head, in high temp baked on silver 66.00
1 Refinish cylinder, in high temp baked on silver 54.00
1 Refinish oil pipe, in high temp baked on silver 5.00
1 Refinish oil pan, in high temp baked on silver 12.00
1 Refinish transmission cover, in high temp baked on silver 7.00
1 Refinish oil filter cover, in high temp baked on silver 5.00
1 Refinish H-cover, black or silver with polished ends 35.00
1 Grind camshaft lobe clearance 40.00
1 Resurface head 30.00
1 Resurface cyinder 30.00
1 Angle cut J Model transmission 144.00
1 Weld crankshaft 75.00
8 Bead blast steel clutch plates. 8.00
1 Complete valve job with APE bronze guides and Viton seals 311.45
1 Labor, motor assembly with cam degree 400.00
1 Install dyno cover rubber grommet 35.00
1 Rebuild starter motor 60.00
1 Rebuild ignition advancer 30.00
1 Polish crank case breather cap 31.25
1 Polish oil fill cap 8.75
1 Polish side oil plug 6.25
1 Polish dyno cover 68.75
1 Polish countershaft sprocket cover 68.75
1 Polish points base cover 31.25
1 Polish points cover 31.25
1 Polish clutch cover 68.75
1 Boring 124.00
1 MTC-J1075 piston kit with (4) forged aluminum pistons with 10.5:1 cranking compression ratio using PSP-3X camshafts, (4) sets of rings, (4) hard chromed wrist pins, ( teflon buttons, (1) one piece copper head gasket and (1) base gasket. 439.95
1 PSP-3X camshafts with .418" lift and 282 degrees of duration at .030" lift. 399.00
6 Kawasaki p/n 92003-208 camshaft sprocket bolts 18.54
1 APE p/n ACS1100K adjustable camshaft sprockets 49.00
1 APE billet cam cover vents 51.00
8 Clutch fiber disks 84.00
2 O'ring Oil pipe 670B2018 2.50
1 O'ring Oil pressure switch 92055-055 2.50
2 O'ring Oil pump & case halves, D-shaped 92055-048 5.00
1 O'ring Oil pan to case 92055-052 5.36
1 O'ring starter snout 92055-1276 6.25
4 O'ring head to cylinder 92055-1148 4.00
1 O'ring cam chain tensioner, 670E2022 8.00
1 O'ring Oil filler cap 92055-049 2.50
1 O'ring Oil side plug 670B2015 1.25
1 O'ring Cam chain tensioner 670E2022 8.00
1 O'ring Crankcase breather o'ring 92055-052 5.36
1 Oil filter with o'rings EM10-37500 6.95
1 Front cam chain guide 12053-1048 31.47
1 Rear cam chain guide 12053-1049 31.47
1 Top cam chain guide 12053-1018 16.76
1 Cam chain KL12-0370 81.09
1 Cam end plugs, SU620-993 15.00
1 H-cover gasket, SU619-606 10.25
1 Transmission cover gasket, COEC061020F 6.30
1 Clutch cover gasket 5.80
1 Oil level window 16.25
1 Overshift bushing 14.00
1 Shift lever return spring 7.50
1 Points base gasket 4.00
4 Intake manifolds (carb holders) 70.00
8 Wire clamp, (2) lower case, (2) under starter, (4) H-cover 18.00
1 Dyno cover gasket 4.00
1 Oil pan gasket 5.30
1 Points cover gasket 4.00
1 Dyno cover rubber grommet, RIGROMMET 13.93
1 APE Heavy Duty Valve Springs VSP500 52.95
4 NGK B8ES spark plugs 10.00
1 Seal kit, KL15-8173 24.95
1 Allen head bolt kit, NGSS-231 35.95
1 Starter motor brush set, Rick's Electrics 24.95
1 Plywood and 2X4 crate 100.00
1 Shipping, 300 pound crate to zip 03755 160.00
1 Engine stand, provides for return shipping safety 50.00
-1 Direct buy discount -72.99
Total with PSP-3X camshafts, pistons to match and adjustable camshaft sprockets. 3726.54

Joe Hooper
Pit Stop Performance
3213 Paisley Circle
Orlando, Florida 32817

TeK9iNe wrote:

OK, very good. Mwahh ha ha

Do you have an impact gun? If so, its going to get some good use now. If not - get one. It doesnt have to be air, electric will work fine, and cheap is ok too, as you're really not going to use it often at all.

HINT - When using an impact gun, you can assist the gun removing a stubborn bolt by twisting on the socket with your hand. This helps greatly!

Just start taking her apart... I recommend removing the dynamo, clutch basket, etc. and you MUST remove the drive sprocket, shift linkage, etc. before splitting the cases.

Read manual - CONTINUE! :laugh:

i took off the ignition stuff from the timing cover. i took off the kick start. i have the bike in gear and am having a hell of a time getting the nut off the front sprocket. i have a air impact, but not a socket big enough. also the nut has been abused and has a chisle groove in it. i tried using a chisel and hammer, but it wont budge. i am afraid that if i get the socket for the nut, that ill strip it worse since it is so fked up. above in my pictures you can see how bad it is. i dont have a torch either.....hmmmmmmmmm

what size is the front sprocket nut?

mine is 27mm, but I have a newer bike...

9am53 wrote:

mine is 27mm, but I have a newer bike...

1.06"

ok, ill wait for a defanite answer before i go get one.

BTW, inches don't exist on this bike...lol...it's a metric bike, you need some new sockets/wrenches!

Mine is 32mm, but it doesn't look the same as yours....mine isn't stepped, it looks like a standard nut. Man, this is