broken cylinder head.....now what?

  • kawifever
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broken cylinder head.....now what?

19 Feb 2014 19:27
#622833
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.
1977 KZ900

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  • bountyhunter
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Re: broken cylinder head.....now what?

19 Feb 2014 19:50
#622836
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.
1979 KZ-750 Twin

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  • kawifever
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Re: broken cylinder head.....now what?

19 Feb 2014 20:03
#622837
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.
1977 KZ900

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  • z1kzonly
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Re: broken cylinder head.....now what?

19 Feb 2014 20:04
#622838
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?
Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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  • kawifever
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Re: broken cylinder head.....now what?

19 Feb 2014 20:56
#622841
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.
1977 KZ900

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  • Puffin
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Re: broken cylinder head.....now what?

20 Feb 2014 03:21
#622847
Just get someone to weld the damaged areas then dril and retap the threads for exhaust studs
KZ1000 J Long Term Owner

KZ1100

KZ1100 Spectre project

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  • 4TheKZ1000
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Re: broken cylinder head.....now what?

20 Feb 2014 03:45 - 20 Feb 2014 03:47
#622848
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.
Last edit: 20 Feb 2014 03:47 by 4TheKZ1000.

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  • fitscott
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Re: broken cylinder head.....now what?

20 Feb 2014 05:05
#622849
I thought KZ900s were only made in 1976??

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  • toolmaker
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Re: broken cylinder head.....now what?

20 Feb 2014 05:16
#622850
fitscott wrote: I thought KZ900s were only made in 1976??
1976 and 1977, then they went to KZ1000's
I live near Portland, Oregon and my rider is a '76 KZ900 I bought new. I'm also in the process of restoring another one and a '73 Z1.

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  • kawifever
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Re: broken cylinder head.....now what?

20 Feb 2014 08:08
#622858
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.
1977 KZ900
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  • zukdave
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Re: broken cylinder head.....now what?

20 Feb 2014 09:26
#622864
Call Pit Stop Performance their a vender on here
they can fix it right..
1980 KZ650 F1
ZX750A1 motor.
Wiseco 810cc kit.
Zukiworks racing ported head.
VM 29 smooth bore's.
Dyna 2000 Ign. w/Dyna mini coil's
APE cylinder stud's and nut's.
APE valve spring's.
APE Track King clutch.
V/H KZ1000 sidewinder.
3.5x18 laced to a KZ1000 disk hub.
150/60/18 Shinko 006 Podium.
63" wheel base.
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  • steell
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Re: broken cylinder head.....now what?

21 Feb 2014 02:41
#622915
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.
KD9JUR

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