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2005 KZ1000P Piston circlip install tool??? 13 Jan 2021 09:36 #841658

  • ken19
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Okay,,, I can get the circlips in with the piston out but my hands are too large or I am too weak to work them in with the piston installed,,, plus the studs are in the way.
I don't feel like losing one ( worse losing it in the engine even though I have rags covering ) so wondering if any of you know of a tool that will work on this engine.

KTM and Pit Posse have a tool but are coy when offering information on fitment. Thanks.

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2005 KZ1000P Piston circlip install tool??? 14 Jan 2021 10:19 #841699

  • ken19
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Guess my question is answered....

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2005 KZ1000P Piston circlip install tool??? 14 Jan 2021 12:01 #841703

  • richard-GPZ
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I am also having the same problem as you with the circlips.
If any one could chime in it sure would help out.
I know my 1983 GPZ-1100 uses an 18mm circlip but don't know if that is all all I need to consider when getting one of these Install Tool.
1983 GPZ-1100 completely stock

1983 Gpz-1100 hot rod build in process

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2005 KZ1000P Piston circlip install tool??? 14 Jan 2021 14:15 #841706

  • krazee1
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I have never used anything other than a quality pair of small needle nose pliers followed by a small pick to rotate the clip to be sure it is seated in the groove. I also used the precautionary towels to seal any possible entry into the depths of the crankcase during a fumble.(about a 50% chance for me) #2 and #3 are a long reach, especially with the cylinder studs in the way, but it helps to do them first at the top of their travel, then rotate the engine to do #1 and #4.

I'm sure a special tool exists, but I never used one at the factory or was aware of one?

Mike
Former M.E. at Kawasaki Motors Manufacturing, Lincoln, NE
1966 W1 (the Z1 of 1966-50H.P. and 100mph!)
1974 Z1A (disassembled)
1976 KZ900B LTD (SOLD!) it's in GOOD Hands!
1978 KZ1000 LTD
1976 KZ900B LTD pile O parts!

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2005 KZ1000P Piston circlip install tool??? 14 Jan 2021 15:49 #841708

  • hardrockminer
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I use my fingers and a small (tiny) blade screwdriver to press the clip into the groove.
I have a couple of Z1B's restored, an '80 KZ1000LTD restored, a 1981 KZ550 restored and a 2008 KLR 650 for off road fun. My wife has a 2019 Suzuki DR 650 for on and off road.

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2005 KZ1000P Piston circlip install tool??? Yesterday 05:47 #841721

  • KZB2 650
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hardrockminer wrote: I use my fingers and a small (tiny) blade screwdriver to press the clip into the groove.


That's pretty much what this first timer did too..... I was worried about one going flying too but didn't have a problem
1978 KZ650 b-2
700cc Wiseco kit 10 to 1.
1980 KZ750 cam, ape springs, stock clutch/ Barnett springs.
Vance and Hines Header w/ comp baffle and Ape pods, Dyna S and green coils, copper wires.
29MM smooth bores W/ 17.5 pilots, 0-6s and 117.5 main
16/42 gearing X ring chain and alum rear JT sprocket.

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2005 KZ1000P Piston circlip install tool??? Yesterday 12:49 #841738

  • DFIGPZ
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krazee1 wrote: I have never used anything other than a quality pair of small needle nose pliers followed by a small pick to rotate the clip to be sure it is seated in the groove. I also used the precautionary towels to seal any possible entry into the depths of the crankcase during a fumble.(about a 50% chance for me) #2 and #3 are a long reach, especially with the cylinder studs in the way, but it helps to do them first at the top of their travel, then rotate the engine to do #1 and #4.

I'm sure a special tool exists, but I never used one at the factory or was aware of one?


Mike


Yes and made sure you lightly file down any nicks you put in piston
1984 GPZ 1100
1170 wiesco 10.5 cr
Larry Cavanaugh head
Bored Throttle bodies
Web .415in cams
Kerker K2 with comp baffle
RC Hp inj
Pogue Adj Regulator

VITON VALVE SEALS $22.00 SET OF 8 SHIPPED TO LOWER 48 PM ME.

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2005 KZ1000P Piston circlip install tool??? Today 21:36 #841771

  • krazee1
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Sorry, not understanding the nick in the piston? I may have launched a circlip or two in my time, but I'm not enough of a klutz to damage a piston installing a wrist pin clip!
(I've had a bit of practice)
Confused, Mike
Former M.E. at Kawasaki Motors Manufacturing, Lincoln, NE
1966 W1 (the Z1 of 1966-50H.P. and 100mph!)
1974 Z1A (disassembled)
1976 KZ900B LTD (SOLD!) it's in GOOD Hands!
1978 KZ1000 LTD
1976 KZ900B LTD pile O parts!

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2005 KZ1000P Piston circlip install tool??? Today 23:26 #841772

  • z1kzonly
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I got a cir-clip story! I know nothing about WTF happened? I bought a bike and the 1075 engine was extra parts. Goof ball Guy tells me, Oh Ya' , new Wiseco 1075 kit, I bent a valve. So he had FBG build him an engine.
So, I take it apart. And find a trashed, rolled oil ring with circlips scoring the liner! That was his bent valve ! Lost compression. Cause of 2 gouges up and down the wall! ??? At least the head was still like new. So I put a new liner in and bored the 1 hole, bought a new Wiseco. and said F the cir-clips. I am using teflon buttons. .234" thickness. I had to take .016" of of the Wiseco wrist pins. I am actually selling this engine on ebay for $1000. I think the said he rode it for 2 miles. So this block has 2 miles on 3 pistons, with 1 new one.
I was at the shop today, slightly cleaning up some early Z1 fork lowers to sell also. Can't shine them too much. Going to clear them like OEM. The Caged Heat is hibernating. Face ass book kicked me off! GOOD! Now I won't waste time. And I can turn that into shop time!
Moral of the story is!
Pay The Man! Sometimes, if your not sure! I always hated cir-clips! I would put a dowel rod thru, slide cir-clip over it. Loose, I have a 17mm in this crank for checking all 4 rods for straightness.
Ebay is a whole new story! They are stopping me end of January for not complying with their new money management system! I am private, no business, no EIN or Tax I.D. #'s They want my Social Security # :angry: :angry: :angry: :angry: :angry:
I don't think so Bob! Sorry to babble. But it was a good day! I even switched a set of 76 LTD dual brakes around to back and made some short lines to hook to the braided hoses. Of course I have pics!
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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