broken cylinder head.....now what?

I recently purchased a 1977 KZ900 with 3500 original miles. This bike was wrecked back in 1978, purchased at an ins. auction and stored inside til I got it. It is almost rust free and I got it running last weekend. So.... here's my problem. I would like to keep this bike as original as possible and get it running down the road with minimal time and money. At least until a can afford a complete resto. However, the cylinder head is broken where two of the exhaust studs bolt into the cylinder head. Other than that I just have a few minor repairs and long overdue maintenence. Can the head be welded? If I have to dig into the engine I feel I might as well bore it out and put bigger pistons in.....etc. Opinions please! Thanks guys.

kawifever wrote: I recently purchased a 1977 KZ900 with 3500 original miles. This bike was wrecked back in 1978, purchased at an ins. auction and stored inside til I got it. It is almost rust free and I got it running last weekend. So.... here's my problem. I would like to keep this bike as original as possible and get it running down the road with minimal time and money. At least until a can afford a complete resto. However, the cylinder head is broken where two of the exhaust studs bolt into the cylinder head. Other than that I just have a few minor repairs and long overdue maintenence. Can the head be welded? If I have to dig into the engine I feel I might as well bore it out and put bigger pistons in.....etc. Opinions please! Thanks guys.

So.... here's my problem.////the cylinder head is broken where two of the exhaust studs bolt into the cylinder head.

If you mean the exhaust studs are broken off, that can be fixed.

Yes the studs are broken off. However, when the studs broke off they also took out a piece of the cylinder head. Basically there is nothing for the studs to screw into as it is broken off of the actual head itself.

With that little miles why bother! You want to spend $750 bucks? New piston kit and machine work? $100 on gaskets. Then you need a head job also. Welcome to the KZ reality show. You want to play you got to pay! $2000 and your done with just the engine! (HA!) then comes the rest. $1000 at Jeff Saunders Z1 enterprise. 2 new tires, brakes etc. Have fun! Hope your wife is cool with it! Ha! Hope I did not ruin your dream.

Heads are a dime a dozen. re-do a head or weld that broke one. You will still have the same engine. 2 vendors on this site can fix anything. So can my guy. Heli-arc the head! wheres a pic of the 3500 mile bike?

You didn't ruin my dream. I know how much these babies cost. That's what I'm trying to postpone for at least one riding season. Besides I like the wrecked 3500 original mile look. Planning on keeping the huge dent in the tank from the last guys knee. Lol. I'll get some pics soon. Just looking for some direction. Was unsure about welding on the head. I know a guy who knows a guy that can get er done. Just don't won't to tear it all apart if I don't have to. Riding season is coming soon and I would like to take it out.

Assuming I get everything fixed and would like to start riding. Do I hook the original odometer that matches the miles on the original tile? Right now they both say exactly 3405 miles.

Just get someone to weld the damaged areas then dril and retap the threads for exhaust studs

You can have the exhaust bosses restored.

They can build up the damaged bosses with weld material, or use a like material to weld in place.

Pick you welder carefully, as their are some rascal's out there.

You will need to tap new holes.

I thought KZ900s were only made in 1976??

fitscott wrote: I thought KZ900s were only made in 1976??

1976 and 1977, then they went to KZ1000's

In 1977 they sold both the kz900 and kz1000. My 1977 KZ900 is basically a left over 1976. Build date is late 1976. I'm not 100% sure but I don't think any kz900 actually have a build date later than 1976.

Call Pit Stop Performance their a vender on here
they can fix it right..

kawifever wrote: In 1977 they sold both the kz900 and kz1000. My 1977 KZ900 is basically a left over 1976. Build date is late 1976. I'm not 100% sure but I don't think any kz900 actually have a build date later than 1976.

Kawasaki build dates start from July of the previous year. For instance a 7/76 build date would be a 77 model, and a 6/76 build date would be a 76 model.