Splitting cases - 1976 KZ900 LTD

Ok guys……I am going to need your help. I have to split my cases. The bike is jumping out of gear when in second back to neutral, and the clutch is slipping when riding down the road at 4-5k rpm’s. I am going to pull the motor, and disassemble to get the tranny out, but I have a few questions.

I am going to go from a 903 cylinder to a 1015 while I have it apart. I am going to get the 70MM rings and rehone the 1015 cylinder to ensure the rings seat properly, but need to know if you think I will need to do anything with the sleeves, or the case otherwise. Some people seem to think they will mate up just fine, others say you need to grind the case to get the sleeves to fit in the case.

Also, while I have pulled many Harley engines apart, I have never done a Kaw big 4. Are there any videos or how to’s on how to pull the transmission? I have the service manual, but they can be convoluted sometimes.

When I start to pull it apart, I was told to make sure that I mark my timing. Can someone please advise the best way to do this? I have stock coils and a Dyna s electronic ignition and she starts first kick everytime right now......I don't want this to change.

When I pull it apart, do I need to do anything special, or watch out for anything like needle bearings falling apart anywhere? Is there any particular area I need to be extra careful? On a Harley, you can tear it down without having to worry about hurting anything, it is when you put it back together you have to make sure you are at TDC to ensure you don’t hurt the valves when you put the rocker boxes on…..but taking them off, you don’t need to worry about anything.

When I put her back together with the 1015, do you think my 26mm carbs will be ok, or will I need to upgrade?

I want this to go as smoothly as possible so I only have to rebuild once. I would appreciate any help you guys are willing to offer. Anyone in the Dayton Ohio area ever done this and want to help?????Beer is on me!!!!!

You can take off the head while still in the bike. That will make it lighter. Pull the cases and remove all the 10mm cap bolts.Get them all. Turn it upside down, remove the pan and oil pump. get all the 10mm bolts around the case too. Suggest you stop, take pics and post them here for advice. The crank main bolts will have to come off except the four center one holding the main cap. There are three threaded holes for you to use the main bolts to split the cases. BE SURE YOU HAVE ALL THE LITTLE BOLTS OUT FIRST. Take the bottom case off exposing the tranny and internals.
BTW all the covers on the sides have to come off as well. Alternator, sprocket cover, ignition cover, clutch cover and kick start cover too.
Do you have a FSM?
Steve

don't forget to remove the bolt hiding under the starter.
i broke a case once because of that lil feller.

leon

There is 30-years old Kawasaki video on youtube how to take engine apart.

531blackbanshee wrote: don't forget to remove the bolt hiding under the starter.
i broke a case once because of that lil feller.

leon

I think there are two under there.
Steve