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Broken Spark Plugs Remedy? 14 Dec 2021 05:01 #859050

  • Dr. Frankenstein
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Yeah, but not enough heat; propane won't do it.  A friend of mine has an acetylene torch but I'm afraid it might melt the aluminum. 

Drilling it out IS an option, but I think that'll be my last resort.

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Broken Spark Plugs Remedy? 14 Dec 2021 06:05 #859056

  • blipco
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Map gas is hotter than propane. It should be enough just to expand the aluminum a tad.
"Swim against the current, even a dead fish can go with the flow"-somebody (I forget Who)

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Broken Spark Plugs Remedy? 14 Dec 2021 06:29 #859058

  • Mikaw
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You should be soaking the broken bit with Kroil or similar. While your searching for a repair option.
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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Broken Spark Plugs Remedy? 14 Dec 2021 08:02 #859061

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You should be soaking the broken bit with Kroil or similar. While your searching for a repair option.
 

Exactly!  Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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Broken Spark Plugs Remedy? 15 Dec 2021 13:10 #859115

  • noman
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pm sent.  
just noticed this head is tapped for 18mm plugs, my 79 has 14mm plugs.  weird.  maybe it's not for a 79 ?

edit:  the spare cyl head is bored/tapped for the oil line, but the casting numbers are different.  maybe it's for a 79' - '80 but the PO drilled for 18mm plugs? 
79 kz400
66 S65

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Broken Spark Plugs Remedy? 20 Dec 2021 16:45 #859394

  • Dr. Frankenstein
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I decided to start at the top and work my way in - doesn't look too bad inside - 
 
 

But the only problem I have right now is getting to the master link...I can rotate the kickstarter but it doesn't seem to be attached to the crank!  It doesn't catch on anything, just seems to rotate through ... Am I missing something obvious here? I'm currently trying to get the right side cover off; all the bolts are out but she doesn't want to give it up off of that stubborn seal the kickstarter shaft goes through...

The points are toast, as I expected...
 

...and the spark advance is too hideous for publication. No pic though.

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Broken Spark Plugs Remedy? 21 Dec 2021 00:32 #859399

  • Scirocco
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But the only problem I have right now is getting to the master link...I can rotate the kickstarter but it doesn't seem to be attached to the crank!  It doesn't catch on anything, just seems to rotate through ... Am I missing something obvious here? I'm currently trying to get the right side cover off; all the bolts are out but she doesn't want to give it up off of that stubborn seal the kickstarter shaft goes through...
 

The cam chain doesn´t have a master link, it´s a endless rivet chain type. You have to remove the cam chain sproket first.

 
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Broken Spark Plugs Remedy? 21 Dec 2021 20:27 #859450

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Gosh, is that all...??

Good thing I have a shop manual. 

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Broken Spark Plugs Remedy? 24 Dec 2021 07:00 #859567

  • noman
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to prevent the cam chain from dropping i suspended mine during head and cyl removal, a little tricky during reassembly.  if the kickstarter doesn't appear to be connected to anything, i believe access to it can be accomplished by flipping the engine over and removing just the bottom case.  the gear train will remain in the upper case, the kickstarter assembly remains in the lower case.  pics are from my 79 kz400 during cleaning and reassembly.  good pic of kickstarter assy in pic#2.     
79 kz400
66 S65
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