Well? Her goes nothin! 78 KZ1000 tear down/rebuild

Thought I'd follow this one to see what you find when you tear it apart. I'm planning on running my '79 1015 motor this summer with 40k on it. I pulled the head and it definitely needs a valve job. I just cleaned it up, replaced a few timing chain parts, put new valve seals in, and put it back together. Was quoted $2000 for a complete rebuild.

BTW, throw that Clymer in the trash. I just got done putting a helicoil in one cam cap hole. As you'll find reading on this site, torque specs are not accurate. I ordered a factory remake off ebay and the LTD suppliment guide as well.

Good luck with it. Doesn't look like they're hard to work on at all. Good advice above already given.

Well thanks for the input. The specs are really the only reason that I bought the damn thing. That and just a troubleshooting guide. So far it's helped a little but like I've stated in other post. This is my first time getting into something like this. Reading through it I've noticed that I may not have the factory carbs and I for sure don't have the air box. But we'll see. Keep an eye on this one. I'll probably post some pics and vids this weekend.

2wheeltom77 wrote: Thought I'd follow this one to see what you find when you tear it apart. I'm planning on running my '79 1015 motor this summer with 40k on it. I pulled the head and it definitely needs a valve job. I just cleaned it up, replaced a few timing chain parts, put new valve seals in, and put it back together. Was quoted $2000 for a complete rebuild.

BTW, throw that Clymer in the trash. I just got done putting a helicoil in one cam cap hole. As you'll find reading on this site, torque specs are not accurate. I ordered a factory remake off ebay and the LTD suppliment guide as well.

Good luck with it. Doesn't look like they're hard to work on at all. Good advice above already given.

Not meaning to hijack this thread but can anybody direct me to a site where I can order the proper manual for my bike. It's a 2002 KZ1000P police bike. It has the J motor. I'm not sure which site to go to or which year to order if I can't find the exact one. I am mainly interested in the motor. I too have the Clymer but can't trust it.

blipco wrote:

2wheeltom77 wrote: quote]

Not meaning to hijack this thread but can anybody direct me to a site where I can order the proper manual for my bike. It's a 2002 KZ1000P police bike. It has the J motor. I'm not sure which site to go to or which year to order if I can't find the exact one. I am mainly interested in the motor. I too have the Clymer but can't trust it.

You can order the service manual and supplement directly from Kawasaki, or a dealer may be able to order it for you. Kawasaki shows the manual @ $74.95 and the supplement @ $19.95. Ronayers.com lists the manual @ $62.06 and the supplement @ $ 16.77. Ed

Attachment kz1000-p21manuals.jpg not found

650ed, thank you. Mark

As you can see she's pretty rough. I want to get er tuned up before I tear er apart if possible. I've went through the carbs and cleaned em up real good inside, filed and gapped points, cleaned the plugs, made up those wires(not sure they belong on this bike but they came with it. figured they have to be better than the broken ones that were on it), replaced the fuel and vac lines, and put a new fuel filter on in. It starts and runs but, it seems like it is missing. I'm not sure that it is being I've never had one but it feels and sounds like there is a miss in it, and the power is less than I had expected. Tomorrow I will post a vid of start up and idle. I don't really know anything about these bikes but I'm not sure these are the right carbs for this year?

Here's some pics hopefully. Wouldn't let me attach them to the last message

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Played with er a little today. Found out I Wasn't getting any spark to the #4 cylinder. Ordered a new coil and managed to clean up the rear master and now I have breaks. Pretty thrilled about that one actually. Sadly I still cant get any photos to upload. Ill Keep tryin.

I hear ya...some days I can't download a pic or reply for some reason and some days it works great...

Check with a multimeter the sparkplug cap, it should have 5000 ohms. They can fail with time and heat. It unscrews from the sparkplug wire and most Japanese motorcycle shops and Z1 enterprises.com sell them. If when re-installing it/them, cut about 1/4" off the end and screw them into the plug wires.

Thanks for the advise. It wasn't a spark plug issue though. The coil wasn't firing.