Top end time

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27 Apr 2020 08:45 #824399 by Greybeard
Top end time was created by Greybeard
The $650 83 KZ1100 3 years of free riding are over.
Time to spend money and pull it apart.
Number 1. Others are dry, but probably not far behind.
1982 KZ1100 D-1
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03 May 2020 07:11 #824841 by Greybeard
Replied by Greybeard on topic Top end time
Cam caps are not easy. Impact hammer freed them. Strange some exhaust were loose. All the rest needed the hammer.
APE make cam cap bolts? Don't think I want to reuse those
1982 KZ1100 D-1
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03 May 2020 07:23 #824842 by CCrosswait
Replied by CCrosswait on topic Top end time
How are the cam cap hole treads? I've had to helicoil a few, as others have pointed out the aluminum threads are a weak link.

Did you check the valve clearances before disassembly? Swapping the tappets with the cams out is infinitely easier.
2019 Indian FTR1200S
2018 Triumph Rocket 3
1981 Kawasaki KZ1100A1
1977 Yamaha RD400
1980 Honda Express II
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03 May 2020 07:38 #824844 by Greybeard
Replied by Greybeard on topic Top end time
I believe I got all the bolts out undamaged. Wasn't easy though.
I just reshimmed it to spec before I started tearing it down.
Don't want to reuse the bolts though.
1982 KZ1100 D-1
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03 May 2020 07:44 #824845 by SWest
Replied by SWest on topic Top end time
Shouldn't be a problem. Mine are 40+ years old. I tighten them by feel. They don't have to be too tight and the torque is measured in inch pounds. Too many guys use foot pounds and mung up the threads.
Steve
Z1b1000 1975 Z1b
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229
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03 May 2020 07:45 #824846 by Greybeard
Replied by Greybeard on topic Top end time
I see the head caps are just as diificult
1982 KZ1100 D-1
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03 May 2020 08:10 - 03 May 2020 08:11 #824847 by Greybeard
Replied by Greybeard on topic Top end time
Head bolts darn near broke my impact hammer, but got them all loose and undamaged. Unlike the top of this impact hammer
1982 KZ1100 D-1
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Last edit: 03 May 2020 08:11 by Greybeard. Reason: Photo

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03 May 2020 08:34 - 03 May 2020 08:34 #824851 by 650ed
Replied by 650ed on topic Top end time
Next time simply soak the fasteners with Kroil for 3 days. No kidding - you will be surprised at the difference in removing them. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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03 May 2020 08:41 - 03 May 2020 08:41 #824852 by Greybeard
Replied by Greybeard on topic Top end time
The oval cylinder head gasket. Not really what I wanted to see.
Build up on #2 and #3 piston dome.
1982 KZ1100 D-1
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Last edit: 03 May 2020 08:41 by Greybeard.

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03 May 2020 08:49 #824854 by Greybeard
Replied by Greybeard on topic Top end time
For a second I thought it was cracked but it's just carbon build up.
1982 KZ1100 D-1
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03 May 2020 08:54 #824857 by Greybeard
Replied by Greybeard on topic Top end time
While I'm waiting on a valve spring compressor to arrive, what's the best way to clean this all up?
1982 KZ1100 D-1

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03 May 2020 11:47 - 03 May 2020 11:48 #824873 by Greybeard
Replied by Greybeard on topic Top end time
Light start on cylinder head surface. A lot came off with a toothbrush and solvent. Light touch with a scotchbrite pad. I'll get the valves better when I remove them for the new valve seals.
1982 KZ1100 D-1
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Last edit: 03 May 2020 11:48 by Greybeard.

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