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1982 KZ100 CSR 15 Oct 2017 15:44 #773005

  • ajsfirehawk
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I found an 82 KZ1000 CSR with 13,500 miles on it. Two owner bike, the guy I bought it from bought it from his next door neighbor. Always garaged, rarely ridden so naturally the tank and carbs were slammed. Rebuilt the carbs and used Metal Rescue on the tank, came out great. Tank has a dent in it and I'll get around to fixing that after it gets ridden for a while. My brother saw it and bought it from me. It is dusty but a clean bike if that makes any sense.


I took it out for a ride after cleaning the carbs/tank, and added a new set of Michelins. Runs great but it was blowing so much oil from the head gasket I brought it back in after just a few miles. So I've striped the head and jugs off of it along with the pan gasket. No way I know of to take the cylinders off without getting a bunch of crap in the crank area, so I always pull the pan and flush it out after cleaning. First time I've ever encountered black gasket sealant on both sides of the cylinders. It is a complete 'Ho' to get this crap off of the black and bottom of the cylinders. 2 hours to clean up the base of the cylinders. Did Kawi start adding sealant to base cylinders in the 80's or has someone had these off and did me a so called favor?

79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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Last edit: by ajsfirehawk.

1982 KZ100 CSR 17 Oct 2017 17:59 #773177

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I really would appreciate some feedback from someone who has pulled an 82 1000cc motor apart. Service manual is very vague about the base cylinder gasket installation.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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1982 KZ100 CSR 18 Oct 2017 06:20 #773208

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The gaskets would have bonded themselves to the surfaces due to heat and age, it's normal, regarding replacement of base gasket you can smear a little grease on the metal surfaces but eventually it will do the same and glue itself to the surfaces, the gaskets only go on one way, and torque to the correct spec.

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1982 KZ100 CSR 18 Oct 2017 10:13 #773234

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Thanks for the response. There is clear difference between the fibrous gasket and the thin layer of black stretchy stuff on both sides of the base. Maybe it is a coating on the gasket that was used. Onward through the fog.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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1982 KZ100 CSR 18 Oct 2017 11:56 #773235

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Then it's more than likely been apart before, black rubbery stuff sounds like some sort of silicone, seen stuff like this before, just keep plugging away at it and use new gaskets on rebuild.

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1982 KZ100 CSR 18 Oct 2017 12:05 #773236

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When rebuilding my 750 I was shocked to see so many different iterations Kawasaki made on some of the gaskets like the head gasket. Some have silicon on them some don't, and all different surface treatments in general. It wouldn't surprise me if Kawasaki had various types of base gaskets for the 1000 as well, maybe related to supplier changes. One other thing I noticed that my 750 engine had RTV between the crankcase halves. I think they were using Threebond 1207B at that time, which is silicone. Maybe they smeared some of that stuff on the base gasket at the corners where the oil feeds up?

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1982 KZ100 CSR 18 Oct 2017 20:07 #773269

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Fascinating. Seems quite possible. I guess at the end of the day it doesn't matter if someone has been in there before or not. I just need to get it clean and install it by the book. Thanks for the thoughts.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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1982 KZ100 CSR 11 Nov 2017 08:56 #774448

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I've been through a few J engine cases at this point, and all had silicone sealant (rubbery) at the case halves, and straight gaskets (no sealant) at the block surface.. Except one which was obviously done by a hacker. The out-of-the-box sealant coating on OEM gaskets doesn't have that rubbery feel at all.
KZ1000-K2
ZRX1100
XR400R

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1982 KZ100 CSR 11 Nov 2017 09:43 #774449

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Thanks for the feedback VTEC. My CSR is an M2. What do you mean by 'J engine"? DO engines have alpha designations as well? Inquiring minds want to know. 8-)

I'm overdue for an update on this one. I put the jugs back on her two days ago. I bought a top end gasket kit that came with the o-ring for the cam in the cylinders where the head mates. It also has the cam chain tensioner o-ring BUT...it did not come with the o-rings for the oil passages. What the hell?? I sent a note to Z1E and asked them to contact their suppliers and suggest the add them to future kits. I had to press them to get them to say they would do so. Let's hope. Silly expensive to buy them individually.

I pulled the fork legs yesterday, dumped the old oil, pulled them apart, put new seals into them as I reassembled them. The allen screw that goes from the bottom of the fork leg to the plunger inside on one of the fork tubes won't tighten. I'm pulling it apart today but it is acting like the plunger threads are stripped. Bad juju. I'll find out today. Wish me luck.

PS - Partzilla no longer sells the plunger assembly. I hope I don't have to scrounge one.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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1982 KZ100 CSR 11 Nov 2017 10:09 #774454

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As far as the forks are concerned. The allen head is most likely turning because you need to hold the the other end (inside the fork) with a special tool. Search on here for a work around. It's been awhile, but may just need something on the end of a long 3/8" extension.

The "J" engine is kind of slang referring to the updated KZ1000/1100 engines (1000 is 998cc, previously 1015cc) that came out in '81 on the "J' model, and were produced all the way up to 2005 on the KZ Police bikes.

Your '82 CSR (M2) is the same bike (engine/frame) as my '82 LTD (K2). The biggest difference is I got mag wheels and different pin stripes.

Don't know what brand head gaskets you're using, and possible they just forgot the o-rings. But look at the diameter of the holes where the 4 outer studs go through. If the diameter is less than that of the inset in the block for the OEM o-rings, then you have a two piece gasket that does not use the outer o-rings. Just like the Cometic one-piece. I don't trust any of them and use strictly OEM.
KZ1000-K2
ZRX1100
XR400R

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Last edit: by VTEC.

1982 KZ100 CSR 11 Nov 2017 12:31 #774459

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The gasket kit is Vesrah made in Japan. Z1E sells them. There is a two piece gasket for the cylinder to head mating surfaces but the opening for the outside studs match the casting. Meaning the countersunk area of the base casting is not covered in any way. Kawasaki brand o-rings are in route.

I was able to tighten the allen screw this morning in the fork base. I have been using two long extensions and a hex head socket, but wasn't able to get it to hold. I tried 15, 16, and 17mm. I should have verified the hex head size before I reassembled. I used a bike master tool, a much more crude piece, tapered four face socket and placed that inside the tube, turned it upside down, leaned on it and was able to tighten the allen screw. I don't like using the bike master tool as I am certain it scars the plunger opening., even if only a small amount. Any port in a storm.

Thanks for the feedback VTEC. Yes, the similarities between the LTD and the CSR are many. Quite clear they are all but twin brothers.

EDIT - Partzilla shows the factory head gasket as two piece as well.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
Z900RS
23 Mach 1

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Last edit: by ajsfirehawk.

1982 KZ100 CSR 11 Nov 2017 14:37 #774462

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Yes. OEM is 2 gaskets and 5 o-rings. The popular (cheap) aftermarket 1 piece/no o-ring gasket is made by Cometic. Did you put a straight edge on the head and block decks once you got them clean?
KZ1000-K2
ZRX1100
XR400R

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