Z750 Engine Rebuild - by a total amateur!

Hi I hold my hands up to that one. In my defence I did try for about an hour to tease it off but it was pretty corroded as the studs showed when I finally got it off. Been looking for a new set of barrels since! I have various service manuals and it will all be getting put together as per spec and going to a machine shop for extra work.

Anyway. Stuck on clutch backing plate screw, the head has disintegrated - the counter sunk one that may be 'staked' in. I hit it with the impact gun but just tore it up even more. Next is the drill and I really hope that works.

But I did get the pistons off!

Braced the rods to limit lateral movement then used a 3/8" extension as a drift to very gently tap the rods out, after removing the rings of course.








One weird thing I noticed about pistons 2 and 3. Number 2 would bot clear the studs but 3 does...?






810cc pistons and a new set of barrels :oops: here soon...

royalratch wrote:

- the counter sunk one that may be 'staked' in. I hit it with the impact gun but just tore it up even more. Next is the drill and I really hope that works.

Yes, the bolts holding the bearing support plate are staked and should be staked again when reassembling, you don't want those bolts coming loose. I played it safe and used a bit of blue Loctite as well.

Drilling the bolt head off should work, it did for me.

Awesome - cheers dude. Only one of them is playing hard ball - the other two came off pretty quick.

How do you stake them?

you mean your not ganna split the cases? you see anything down there with a flashlight? your doing well. i remember i took my motor apart. splitting the cases was the hardest part. just gatta be careful. keep asking questions, we wont get tired of em....well exept for my questions anyway. lol. keep on gettin it fellow kzer....Joe

Cheers dude.

I am splitting the cases - total tear down, paint and rebuild.

How does splitting the cases help here? Do I need them separated to stake it correctly?

royalratch wrote:

How do you stake them?

You take a pointy punch, set it at the perimeter of the bolt head and give the punch a solid whack or two with a hammer - this creates a dimple in the bolt head and the surrounding material that prevents the bolt from rotating.

The pic below shows the kickstart shaft retaining bracket on a 650 engine, the stake marks are circled in red:

No eBay APP ID and/or Cert ID defined in Kunena configurationNo eBay APP ID and/or Cert ID defined in Kunena configurationLooking for a Block? Maybe here, cheap!
cgi.ebay.com/ebaymotors/Kawasaki-KZ750-C...&hash=item2a0d6ac38d

Or this, a bit more:
cgi.ebay.com/ebaymotors/82-KAWASAKI-KZ75...&hash=item5889d4e31e

Remember in this case "Installation is NOT the the reverse of Removal" :laugh:

@OnkelB - cheers dude.; Doesn't that do damage to the block? Or is it only the plate which will then need to be replaced if you need to remove again?

I'm in the UK so USA parts are not really an option. I have a lead on one via z1ownersclub here in the UK so it's all good.

Pistons have arrived - behold!

First, OTT packaging with legendary 'forged' and 'performance' scripts present!




Graphite headgasket - supposed to kill oil leaks once and fro all. And it's graphite!





Obviously they sell a lot of V8 kits!



Rings included - these are £200 for a complete set of Kawasaki ones alone...?





And the pistons! Machined perfection with valve recesses for the immense power of the... 800!







Shame I got no barrels to put them in!

No eBay APP ID and/or Cert ID defined in Kunena configurationWiseco has always made quality components.
Here is a link to the US Post Office, you should be able to easily figure out shipping from the USA. These are on Ebay all the time. 1 Of those is still for sale I see, $50USD, whats that in Euro's?
ircalc.usps.gov/

Here is another auction, this will probably go real cheap. Ask if he will do International, give him your thread link maybe?
cgi.ebay.com/ebaymotors/1980-KAWASAKI-KZ...&hash=item2a0d90d1db

congrats on the new pistons ratch.
wiseco has a really nice product.

keep us posted on your build,

leon

I got these from an eBay seller but didn't do the deal via eBay. Price was very good including shipping to the UK. For what you get in the kit, it's very good value.