Terrible motor swap idea kz440

wrote:

Alright guys I need your help! I can't tell if these jets are different from standard sizes. My main curiosity is to see whether they are jetted for pods since it didn't come with an airbox. Thanks in advance! 

 

If it had pipe/pods look to see if it has stock needles which have no adjustment clips.

Most likely it will have some sort of DynoJet brand kit (3 stages) to get it running right without the air box. Aftermarket needles are slotted with clips for adjustment, might also explain the funky main jets.

I need help badly!!! I tried turning the engine over and it would only go about 180 degrees and I did it gently but I could see the valves going to contact the pistons through the spark plug hole!!! Through this discovery I pulled the valve cover and ultimately pulled the heads. In using the physical manual that came with the bike i discovered a lot of fingerprints in the camshaft and cylinder head removal section so clearly someone pulled them so I was thinking that maybe they installed them wrong? There is no damage that I can see so I'm thinking they couldn't start the bike. I need input for what to do!!!   

Possible the valve timing was set incorrectly, it doesn't look like it was spun on the starter as there doesn't appear to be any witness marks on the pistons or valves (maybe this is why the PO disassembled it !!)

Since you have gone this far, you should remove the cylinder and pistons, so everything can be inspected and cleaned.  Also, remove the valves from the head for similar.  

Those bikes are known to spin rod bearings, so check for free rotation and no big lateral play in the rods.  

bound wrote:

I need help badly!!! I tried turning the engine over and it would only go about 180 degrees and I did it gently but I could see the valves going to contact the pistons through the spark plug hole!!! Through this discovery I pulled the valve cover and ultimately pulled the heads. In using the physical manual that came with the bike i discovered a lot of fingerprints in the camshaft and cylinder head removal section so clearly someone pulled them so I was thinking that maybe they installed them wrong? There is no damage that I can see so I'm thinking they couldn't start the bike. I need input for what to do!!! 

I would suggest you re-fit the head and cams with the old head gasket following the manual for assembly and camshaft timing. Once done see if it now turns manually through a couple of full rotations

I dont think I'll be doing that any time soon since when I took the head off there was no gasket  . I got a gasket kit online coming in the mail so i think I'll take a peek in the rest of the engine. I gotta say though, not as a sign of wear, but these cams look pretty good. At least better than my kz1000 with 20,000 miles. 

bound wrote:

I dont think I'll be doing that any time soon since when I took the head off there was no gasket 

. I got a gasket kit online coming in the mail so i think I'll take a peek in the rest of the engine. I gotta say though, not as a sign of wear, but these cams look pretty good. At least better than my kz1000 with 20,000 miles.

I don't know how much piston to valve clearance these run but having no gasket could be the cause of the "lock up"

That's what I thought at first but I dont think the intake valve would be open when the piston is coming up, only when going down but in no motor expert.

The inlet begins to open 30 - 40 degrees before TDC

Wookie58 wrote:

bound wrote:

I dont think I'll be doing that any time soon since when I took the head off there was no gasket 

. I got a gasket kit online coming in the mail so i think I'll take a peek in the rest of the engine. I gotta say though, not as a sign of wear, but these cams look pretty good. At least better than my kz1000 with 20,000 miles.

I don't know how much piston to valve clearance these run but having no gasket could be the cause of the "lock up"

 

I would agree this is the case as GPZ version engines always seem to have a higher compression piston as compared to the KZ versions of the same displacement (higher dome) Assembling without a head gasket would put the valves too close to the pistons for sure, and if your one tooth out either way there would be "interference".