Top end rebuild 78 kz1000

DFIGPZ wrote: 60,000 miles and you plan to keep bike ? split the cases and do it right you are well on your way to worn parts I can bet the clutch hub is loose, trans dogs worn, crank ? can chain history, cylinder studs will be weak, valve guides shot, valve seals gone, Valves ? , Valve springs shot you will be suprised what you find do it right and you should see 60,000 more miles out of her, When I was A Kawasaki Mechanic I had a customer bring in a 1974 Z1 900 with 100,000 on the clock she was using some oil and was a little down on power customer thought it would be a engine rering till i tore i down but he was happy to fix it the correct way said it [ bike ] didn't owe anymore we rebuilt it and away he went he just loved that bike he bought it new in 74 put a wind jammer on it and went every where on it.

I am using the 77 engine that has around 30,000+ miles on it, last Winter I split the cases and replaced "ALL' the rubber o rings and seals also the output shaft that had messed up sprocket splines , the gears are fine, I am going to trust the crank and cam chain but I still plan on measuring the chain,
I ran this engine in my bike last year for around 9,000 miles and no trouble from the bottom end, just low compression.
The head off my 78 engine went to Larry C and is getting new seals along with A.P.E. valves and springs and that is going on top of the 77
The pistons and jugs are well within tolerances and the new rings are looking good.

I need to figure out how to loose 3.5 grams of aluminum off the # 3 piston


The plan is to totally rebuild the 78 motor over time and possibly go with a 1075 kit.

bluezbike wrote: Did you weigh the pistons with their respective pins?

Weighed the wrist pins and no help,
1-- 58.5 grams
2-- 58.5
3-- 58.8
4-- 58.8
This is what 3.5 grams of aluminum looks like .