There are no Phillips heads screws on any KZ model; that's why the cross head screw stripped. The writeup below has a section that explains the problem.

Many newbies and not so newbies run into or issues with their bikes which could be easily avoided with a little preparation or information. Here are a couple recommendations that I hope you will find useful.

Before riding your KZ you should take a little time to become familiar with it. Simple things like checking the oil, tire pressures, etc. are explained in the Kawasaki Owner's Manual. If you bike didn't come with one (they normally are in a little holder on the bottom of the seat) you can usually find one on eBay - be sure to get one for your exact year/model.


MANUAL

You really should consider buying the Kawasaki Factory Service Manual for your bike. The factory service manual provides instructions on the various maintenance procedures and schedules for your bike, procedures for diagnosing problems, proper torque values for the various fasteners (VERY IMPORTANT), and insight into how each system on your bike works even if you are not repairing that system. Studying the manual before you attempt performing service on your bike will impart an understanding of the system you are working on which will increase the odds of success.

The manuals usually are readily available for most models on eBay and other sources; but be sure to get one that has your specific year and model in it as there are differences between the various KZ650 models. I do not recommend Clymers, Haynes, or other aftermarket manuals as I have seen instances where they provide inaccurate advice. You may decide to use those to supplement the factory manual, but in my opinion they are not a suitable substitute. If you have trouble finding one for your model ask us to help.


TOOLS

WARNING! Do not even try to use Phillips screwdrivers on the Kawasaki cross head screws. Despite their appearance they are not Phillips screws. They are Japanese Industrial Standard (JIS) screws. The tips of Phillips screwdrivers are too long & pointed to allow the 4 blades of the screwdriver to properly engage the screws, so when you apply force the screw head slots will deform and look like crap. The fact is that Phillips screws were deliberately designed to have the screwdriver bit "cam out." This was done to prevent production line assembly from over-tightening, stripping, or breaking the screws. JIS screws do not have this problem. A proper fitting JIS bit can tighten a JIS screw to and beyond the torque spec without camming out. Here's the good news - you can easily modify standard Phillips screwdriver tips to fit the JIS screws.

I have ground down the tips of DeWalt #2 and DeWalt #3 Phillips to make them fit JIS screws. The large crosshead screws on the cases take modified #3 bits (or genuine #3 JIS bits). To modify the DeWalt bits you need to grind the very tip a little, then test fit, then grind a little more and test fit, etc. until the bit no longer "rocks" back and forth in the screwhead. Picture 1 below shows how a DeWalt #3 bit fits the case screws of my KZ650 after being ground properly. The #2 DeWalt bits can be modified the same way to fit smaller JIS screws. Pictures 2 and 3 below shows DeWalt #2 and #3 modified bits.

I did find a place that sells authentic JIS bits. They don't list the #3 bit, but if you contact them they can provide the #3 JIS bits even though they are not listed on the website. These folks were very easy to work with, and the authentic bits do work great. Here's their site:

www.rjrcooltools.com/shop_item_detail.cfm?subcat_ID=89

Pictures 4 & 5 below show a comparison between my home made modified bits with the authentic JIS bits.

PICTURE 1


PICTURE 2


PICTURE 3


PICTURE 4


PICTURE 5


Before reaching for that wrench or ratchet consider the following. The bolts are steel, but your engine and front forks are aluminum. The bolts are much tougher than the aluminum and if over tightened will strip the aluminum threads. Although these can be repaired, preventing damage by applying proper torque will save you grief, time, and money. Tightening fasteners properly requires torque wrenches. Various vendors, including Snap-on, CDI, Sears, etc., market torque wrenches. The two most popular types are the bar type and micrometer type. Either will work, but the micrometer type is a bit easier to use, especially if you are tightening several fasteners with the same torque - such as cylinder head covers. You will need a torque wrench calibrated in INCH POUNDS for many of the bolts. You will also need a torque wrench calibrated in FOOT POUNDS for the larger bolts. Don't try to use the foot pounds wrench on the smaller bolts as it will not be sensitive enough at low torque settings to provide accurate torque. There are many fasteners that require low torque. These include such things as 6mm oil pan bolts, cylinder head cover bolts, etc. for which the torque in 61-78 inch pounds. These low torque bolts require a wrench that is accurate at low settings and this wrench should be graduated in inch pounds. In addition, there are numerous high torque fasteners such as the front axle nuts (51 - 65 foot pounds) or swing arm pivot shaft nuts (58 - 87 foot pounds). These require a wrench that is accurate at higher settings; this wrench should be graduated in foot pounds. Using the proper torque wrenches to correctly tighten fasteners will help prevent damage and contribute to a safe bike. The Kawasaki Service Manual will list the various torque specs for the bolts. I suggest you get the manual before buying the torque wrenches so you can decide which wrenches best meet the torque specs.

Consider buying a can of Kroil penetrating oil and use it to soak stubborn fasteners for a couple days before trying to loosen them. Remember, the original screws and bolts were installed on your bike when Jimmy Carter was President, so many of them may be hard to remove. Kroil can be bought online, at guns shows, and at some other venues.


MOTOR OIL
The ingredients in oils have changed over the years. For example, today's Castrol GTX (and pretty much all AUTOMOBILE oil) is not the same as it was in the 1980's. Back then it worked great in KZ bikes, but things have changed. Zinc and phosphorus additives (ZDDP), important to protect engine components from metal to metal contact, has been reduced since it’s been found to shorten catalytic converter life. Today’s auto oils contain about ½ the ZDDP they used to and different additives have been developed as substitutes. Unfortunately, some of these newer additives, in particular molybdenum disulfide, don’t get along with the wet clutches in our bikes. Newer oils, especially those labeled “Energy Conserving” (EC), which have a high quantity of friction reducing additives, should be avoided. These oils work fine in automobiles but there are better choices for motorcycles.

KZ bikes need oil which is suitable for wet clutches. That distinction was defined by the Japanese Engine Oil Standards Implementation Panel (JASO), and can be noted by oils that meet the "4T” (4 cycle) specification, MA (wet clutch) classification. These oils, which include various synthetic, semi-synthetic, and non-synthetic oils, are sold as specific motorcycle oils. Another type of oil which works well in our bikes is diesel engine oil. These oils are governed by the API (American Petroleum Institute) CI-4/CJ-4 spec and don’t contain clutch-damaging EC additives. You can even purchase Shell Rotella oil which holds a “JASO-MA” certification assuring it will get along well with your wet clutch. All of these newer oils have a reduced ZDDP level too (about 1/3 less than before instead of ½ like the auto oils) but the substitute additives get along better with our bikes needs than automotive oil. Oils that do not hold the JASO-MA rating have either failed the wet clutch test or have not been tested for use in engines with wet clutches. Good luck with the bike! Ed

GSXR1000 swingarm

Welcome aboard -

Here are some tips that you may find helpful:

Many newbies and not so newbies run into or issues with their bikes which could be easily avoided with a little preparation or information. Here are a couple recommendations that I hope you will find useful.

Before riding your KZ you should take a little time to become familiar with it. Simple things like checking the oil, tire pressures, etc. are explained in the Kawasaki Owner's Manual. If you bike didn't come with one (they normally are in a little holder on the bottom of the seat) you can usually find one on eBay - be sure to get one for your exact year/model.


MANUAL

You really should consider buying the Kawasaki Factory Service Manual for your bike. The factory service manual provides instructions on the various maintenance procedures and schedules for your bike, procedures for diagnosing problems, proper torque values for the various fasteners (VERY IMPORTANT), and insight into how each system on your bike works even if you are not repairing that system. Studying the manual before you attempt performing service on your bike will impart an understanding of the system you are working on which will increase the odds of success.

The manuals usually are readily available for most models on eBay and other sources; but be sure to get one that has your specific year and model in it as there are differences between the various KZ650 models. I do not recommend Clymers, Haynes, or other aftermarket manuals as I have seen instances where they provide inaccurate advice. You may decide to use those to supplement the factory manual, but in my opinion they are not a suitable substitute. If you have trouble finding one for your model ask us to help.


TOOLS

WARNING! Do not even try to use Phillips screwdrivers on the Kawasaki cross head screws. Despite their appearance they are not Phillips screws. They are Japanese Industrial Standard (JIS) screws. The tips of Phillips screwdrivers are too long & pointed to allow the 4 blades of the screwdriver to properly engage the screws, so when you apply force the screw head slots will deform and look like crap. The fact is that Phillips screws were deliberately designed to have the screwdriver bit "cam out." This was done to prevent production line assembly from over-tightening, stripping, or breaking the screws. JIS screws do not have this problem. A proper fitting JIS bit can tighten a JIS screw to and beyond the torque spec without camming out. Here's the good news - you can easily modify standard Phillips screwdriver tips to fit the JIS screws.

I have ground down the tips of DeWalt #2 and DeWalt #3 Phillips to make them fit JIS screws. The large crosshead screws on the cases take modified #3 bits (or genuine #3 JIS bits). To modify the DeWalt bits you need to grind the very tip a little, then test fit, then grind a little more and test fit, etc. until the bit no longer "rocks" back and forth in the screwhead. Picture 1 below shows how a DeWalt #3 bit fits the case screws of my KZ650 after being ground properly. The #2 DeWalt bits can be modified the same way to fit smaller JIS screws. Pictures 2 and 3 below shows DeWalt #2 and #3 modified bits.

I did find a place that sells authentic JIS bits. They don't list the #3 bit, but if you contact them they can provide the #3 JIS bits even though they are not listed on the website. These folks were very easy to work with, and the authentic bits do work great. Here's their site:

www.rjrcooltools.com/shop_item_detail.cfm?subcat_ID=89

Pictures 4 & 5 below show a comparison between my home made modified bits with the authentic JIS bits.

PICTURE 1


PICTURE 2


PICTURE 3


PICTURE 4


PICTURE 5


Before reaching for that wrench or ratchet consider the following. The bolts are steel, but your engine and front forks are aluminum. The bolts are much tougher than the aluminum and if over tightened will strip the aluminum threads. Although these can be repaired, preventing damage by applying proper torque will save you grief, time, and money. Tightening fasteners properly requires torque wrenches. Various vendors, including Snap-on, CDI, Sears, etc., market torque wrenches. The two most popular types are the bar type and micrometer type. Either will work, but the micrometer type is a bit easier to use, especially if you are tightening several fasteners with the same torque - such as cylinder head covers. You will need a torque wrench calibrated in INCH POUNDS for many of the bolts. You will also need a torque wrench calibrated in FOOT POUNDS for the larger bolts. Don't try to use the foot pounds wrench on the smaller bolts as it will not be sensitive enough at low torque settings to provide accurate torque. There are many fasteners that require low torque. These include such things as 6mm oil pan bolts, cylinder head cover bolts, etc. for which the torque in 61-78 inch pounds. These low torque bolts require a wrench that is accurate at low settings and this wrench should be graduated in inch pounds. In addition, there are numerous high torque fasteners such as the front axle nuts (51 - 65 foot pounds) or swing arm pivot shaft nuts (58 - 87 foot pounds). These require a wrench that is accurate at higher settings; this wrench should be graduated in foot pounds. Using the proper torque wrenches to correctly tighten fasteners will help prevent damage and contribute to a safe bike. The Kawasaki Service Manual will list the various torque specs for the bolts. I suggest you get the manual before buying the torque wrenches so you can decide which wrenches best meet the torque specs.

Consider buying a can of Kroil penetrating oil and use it to soak stubborn fasteners for a couple days before trying to loosen them. Remember, the original screws and bolts were installed on your bike when Jimmy Carter was President, so many of them may be hard to remove. Kroil can be bought online, at guns shows, and at some other venues.


MOTOR OIL
The ingredients in oils have changed over the years. For example, today's Castrol GTX (and pretty much all AUTOMOBILE oil) is not the same as it was in the 1980's. Back then it worked great in KZ bikes, but things have changed. Zinc and phosphorus additives (ZDDP), important to protect engine components from metal to metal contact, has been reduced since it’s been found to shorten catalytic converter life. Today’s auto oils contain about ½ the ZDDP they used to and different additives have been developed as substitutes. Unfortunately, some of these newer additives, in particular molybdenum disulfide, don’t get along with the wet clutches in our bikes. Newer oils, especially those labeled “Energy Conserving” (EC), which have a high quantity of friction reducing additives, should be avoided. These oils work fine in automobiles but there are better choices for motorcycles.

KZ bikes need oil which is suitable for wet clutches. That distinction was defined by the Japanese Engine Oil Standards Implementation Panel (JASO), and can be noted by oils that meet the "4T” (4 cycle) specification, MA (wet clutch) classification. These oils, which include various synthetic, semi-synthetic, and non-synthetic oils, are sold as specific motorcycle oils. Another type of oil which works well in our bikes is diesel engine oil. These oils are governed by the API (American Petroleum Institute) CI-4/CJ-4 spec and don’t contain clutch-damaging EC additives. You can even purchase Shell Rotella oil which holds a “JASO-MA” certification assuring it will get along well with your wet clutch. All of these newer oils have a reduced ZDDP level too (about 1/3 less than before instead of ½ like the auto oils) but the substitute additives get along better with our bikes needs than automotive oil. Oils that do not hold the JASO-MA rating have either failed the wet clutch test or have not been tested for use in engines with wet clutches. Good luck with the bike! Ed

The rear suspension on the other hand is going to be a completely different story... the swing arm is hitting the foot peg mounts
So I'll have to cut the mounts off and smooth the frame out and see where it's at after that.
The next issue is the Grand Canyon size gap between the inner frame and the outer of the swing arm pivot. this is not a huge issue seeing as the GSXR pivot bolt sits slightly recessed into the swing arm so the gap is easily corrected by machining a metal washer/bushing to the correct dimensions to get everything squared up and make it a snug fit.
The next issue is the GSXR pivot bolt is twice the size of the KZ, so much so they fit inside each other with room to spare :laugh: I can bore the swing arm pivot hole to the same size as the GSXR bolt no problem, my only concern is that the GSXR bolt is almost the same size as the welded in bushing,

My last issue is, even though I thought my string was pretty funny! I have some doubts about it holding up under serious riding conditions :laugh: I'll be putting a mounting bar across the frame almost directly above the swing arm pivot with a mounting tab, add a similar mounting tab to the lower bar where the center stand was while attempting to keep as close to correct geometry as possible. Finally I'll have to figure out where to stuff the battery seeing as there will be a shock where the battery box used to be?

I use Bel Ray Waterproof Grease on wheel bearings and steering stem; Mobil-1 synthetic grease on swing arm bushings; Mobil-1 synthetic oil inside cables; Bosch Distributor Cam Grease on the ignition points cam; Maxima Chain Wax on the drive chain; Mobil-1 Racing 4T Oil full synthetic oil in crankcase; and Prestone DOT-3 (syn) brake fluid in the brake reservoirs. Ed

Here are some additional tips that you may find helpful:

Many newbies and not so newbies run into or issues with their bikes which could be easily avoided with a little preparation or information. Here are a couple recommendations that I hope you will find useful.

Before riding your KZ you should take a little time to become familiar with it. Simple things like checking the oil, tire pressures, etc. are explained in the Kawasaki Owner's Manual. If you bike didn't come with one (they normally are in a little holder on the bottom of the seat) you can usually find one on eBay - be sure to get one for your exact year/model.


MANUAL

You really should consider buying the Kawasaki Factory Service Manual for your bike. The factory service manual provides instructions on the various maintenance procedures and schedules for your bike, procedures for diagnosing problems, proper torque values for the various fasteners (VERY IMPORTANT), and insight into how each system on your bike works even if you are not repairing that system. Studying the manual before you attempt performing service on your bike will impart an understanding of the system you are working on which will increase the odds of success.

The manuals usually are readily available for most models on eBay and other sources; but be sure to get one that has your specific year and model in it as there are differences between the various KZ650 models. I do not recommend Clymers, Haynes, or other aftermarket manuals as I have seen instances where they provide inaccurate advice. You may decide to use those to supplement the factory manual, but in my opinion they are not a suitable substitute. If you have trouble finding one for your model ask us to help.


TOOLS

WARNING! Do not even try to use Phillips screwdrivers on the Kawasaki cross head screws. Despite their appearance they are not Phillips screws. They are Japanese Industrial Standard (JIS) screws. The tips of Phillips screwdrivers are too long & pointed to allow the 4 blades of the screwdriver to properly engage the screws, so when you apply force the screw head slots will deform and look like crap. The fact is that Phillips screws were deliberately designed to have the screwdriver bit "cam out." This was done to prevent production line assembly from over-tightening, stripping, or breaking the screws. JIS screws do not have this problem. A proper fitting JIS bit can tighten a JIS screw to and beyond the torque spec without camming out. Here's the good news - you can easily modify standard Phillips screwdriver tips to fit the JIS screws.

I have ground down the tips of DeWalt #2 and DeWalt #3 Phillips to make them fit JIS screws. The large crosshead screws on the cases take modified #3 bits (or genuine #3 JIS bits). To modify the DeWalt bits you need to grind the very tip a little, then test fit, then grind a little more and test fit, etc. until the bit no longer "rocks" back and forth in the screwhead. Picture 1 below shows how a DeWalt #3 bit fits the case screws of my KZ650 after being ground properly. The #2 DeWalt bits can be modified the same way to fit smaller JIS screws. Pictures 2 and 3 below shows DeWalt #2 and #3 modified bits.

I did find a place that sells authentic JIS bits. They don't list the #3 bit, but if you contact them they can provide the #3 JIS bits even though they are not listed on the website. These folks were very easy to work with, and the authentic bits do work great. Here's their site:

www.rjrcooltools.com/shop_item_detail.cfm?subcat_ID=89

Pictures 4 & 5 below show a comparison between my home made modified bits with the authentic JIS bits.

PICTURE 1


PICTURE 2


PICTURE 3


PICTURE 4


PICTURE 5


Before reaching for that wrench or ratchet consider the following. The bolts are steel, but your engine and front forks are aluminum. The bolts are much tougher than the aluminum and if over tightened will strip the aluminum threads. Although these can be repaired, preventing damage by applying proper torque will save you grief, time, and money. Tightening fasteners properly requires torque wrenches. Various vendors, including Snap-on, CDI, Sears, etc., market torque wrenches. The two most popular types are the bar type and micrometer type. Either will work, but the micrometer type is a bit easier to use, especially if you are tightening several fasteners with the same torque - such as cylinder head covers. You will need a torque wrench calibrated in INCH POUNDS for many of the bolts. You will also need a torque wrench calibrated in FOOT POUNDS for the larger bolts. Don't try to use the foot pounds wrench on the smaller bolts as it will not be sensitive enough at low torque settings to provide accurate torque. There are many fasteners that require low torque. These include such things as 6mm oil pan bolts, cylinder head cover bolts, etc. for which the torque in 61-78 inch pounds. These low torque bolts require a wrench that is accurate at low settings and this wrench should be graduated in inch pounds. In addition, there are numerous high torque fasteners such as the front axle nuts (51 - 65 foot pounds) or swing arm pivot shaft nuts (58 - 87 foot pounds). These require a wrench that is accurate at higher settings; this wrench should be graduated in foot pounds. Using the proper torque wrenches to correctly tighten fasteners will help prevent damage and contribute to a safe bike. The Kawasaki Service Manual will list the various torque specs for the bolts. I suggest you get the manual before buying the torque wrenches so you can decide which wrenches best meet the torque specs.

Consider buying a can of Kroil penetrating oil and use it to soak stubborn fasteners for a couple days before trying to loosen them. Remember, the original screws and bolts were installed on your bike when Jimmy Carter was President, so many of them may be hard to remove. Kroil can be bought online, at guns shows, and at some other venues.


MOTOR OIL
The ingredients in oils have changed over the years. For example, today's Castrol GTX (and pretty much all AUTOMOBILE oil) is not the same as it was in the 1980's. Back then it worked great in KZ bikes, but things have changed. Zinc and phosphorus additives (ZDDP), important to protect engine components from metal to metal contact, has been reduced since it’s been found to shorten catalytic converter life. Today’s auto oils contain about ½ the ZDDP they used to and different additives have been developed as substitutes. Unfortunately, some of these newer additives, in particular molybdenum disulfide, don’t get along with the wet clutches in our bikes. Newer oils, especially those labeled “Energy Conserving” (EC), which have a high quantity of friction reducing additives, should be avoided. These oils work fine in automobiles but there are better choices for motorcycles.

KZ bikes need oil which is suitable for wet clutches. That distinction was defined by the Japanese Engine Oil Standards Implementation Panel (JASO), and can be noted by oils that meet the "4T” (4 cycle) specification, MA (wet clutch) classification. These oils, which include various synthetic, semi-synthetic, and non-synthetic oils, are sold as specific motorcycle oils. Another type of oil which works well in our bikes is diesel engine oil. These oils are governed by the API (American Petroleum Institute) CI-4/CJ-4 spec and don’t contain clutch-damaging EC additives. You can even purchase Shell Rotella oil which holds a “JASO-MA” certification assuring it will get along well with your wet clutch. All of these newer oils have a reduced ZDDP level too (about 1/3 less than before instead of ½ like the auto oils) but the substitute additives get along better with our bikes needs than automotive oil. Oils that do not hold the JASO-MA rating have either failed the wet clutch test or have not been tested for use in engines with wet clutches. Good luck with the bike! Ed

So It seems I have really bad timing, seems my original thread was lost in the upgrade. (Thanks bill for trying to find it.) Lets try this again...

In November I found this on Craigslist.

'83 KZ1100ltd, previous owner had started building a "bobber", but went about it in a different way, using a J model 1000 engine for chain drive and giving it the forks, swing arm, wheels and brakes from a Suzuki Bandit 1200, made for a better than average looking "bobber", however I can only imagine what a kidney killer this would have been with the combination of struts, a 180/55/17 rear tire and a thinly padded piece of aluminum that passed for a seat...

The seat and tail are from a GPZ1100 found on ebay being sold by a local mc salvage, the shocks are from a ZXR that I had for another project.

A few more ebay scores, first gen Ninja 900 fairing, Vance and Hines pipe, and the tail from my Nighthawk s and the vision starts to take shape

fast forward about a month, the plugs for the side covers and tail are done, (the plugs were painted for better mold release and to get a better look how the bike will look when done.) molds are also done.

Cheers Beers n Gearz, Joe

Hello again, here are some pictures from my January progress.
ZX9R rear wheel and chain / rear sprocket adjustments.

Facts:
Z1B swing arm inner width 250 mm
ZX9R swing arm inner width 265 mm

Z1B axle diameter 20 mm
ZX9B axle diameter 25 mm

+ 15 mm for wheel, disc brake parts and rear sprocket holder to fit in my swing arm.
+ 5 mm for the bearings and Z1B swing arm axle.

Impossible but not really.

My solution:

I cut the ZX9R axle to 249 mm length and bore it out to 20,15 mm inner diameter.
So i can slide through my special axle for the eccentric chain adjustment. +5 mm problem solved.
The rear sprocket holder inner bore for the bearing was drilled 4 mm deeper on the lathe.
The supporting surface for the rear sprocket was machined off 10 mm and the front surface was shorted
( i don't know exactly but i think is was 12 mm ).
Shorten the spacer sleeve for the sealing and bearing support to 12 mm length. +15 mm problem solved.

I hope it is understandable for everybody, if not i will make same exactly measurements and pictures.

Welcome aboard -

Here are some tips that you may find helpful:

Many newbies and not so newbies run into or issues with their bikes which could be easily avoided with a little preparation or information. Here are a couple recommendations that I hope you will find useful.

Before riding your KZ you should take a little time to become familiar with it. Simple things like checking the oil, tire pressures, etc. are explained in the Kawasaki Owner's Manual. If you bike didn't come with one (they normally are in a little holder on the bottom of the seat) you can usually find one on eBay - be sure to get one for your exact year/model.


MANUAL

You really should consider buying the Kawasaki Factory Service Manual for your bike. The factory service manual provides instructions on the various maintenance procedures and schedules for your bike, procedures for diagnosing problems, proper torque values for the various fasteners (VERY IMPORTANT), and insight into how each system on your bike works even if you are not repairing that system. Studying the manual before you attempt performing service on your bike will impart an understanding of the system you are working on which will increase the odds of success.

The manuals usually are readily available for most models on eBay and other sources; but be sure to get one that has your specific year and model in it as there are differences between the various KZ650 models. I do not recommend Clymers, Haynes, or other aftermarket manuals as I have seen instances where they provide inaccurate advice. You may decide to use those to supplement the factory manual, but in my opinion they are not a suitable substitute. If you have trouble finding one for your model ask us to help.


TOOLS

WARNING! Do not even try to use Phillips screwdrivers on the Kawasaki cross head screws. Despite their appearance they are not Phillips screws. They are Japanese Industrial Standard (JIS) screws. The tips of Phillips screwdrivers are too long & pointed to allow the 4 blades of the screwdriver to properly engage the screws, so when you apply force the screw head slots will deform and look like crap. The fact is that Phillips screws were deliberately designed to have the screwdriver bit "cam out." This was done to prevent production line assembly from over-tightening, stripping, or breaking the screws. JIS screws do not have this problem. A proper fitting JIS bit can tighten a JIS screw to and beyond the torque spec without camming out. Here's the good news - you can easily modify standard Phillips screwdriver tips to fit the JIS screws.

I have ground down the tips of DeWalt #2 and DeWalt #3 Phillips to make them fit JIS screws. The large crosshead screws on the cases take modified #3 bits (or genuine #3 JIS bits). To modify the DeWalt bits you need to grind the very tip a little, then test fit, then grind a little more and test fit, etc. until the bit no longer "rocks" back and forth in the screwhead. Picture 1 below shows how a DeWalt #3 bit fits the case screws of my KZ650 after being ground properly. The #2 DeWalt bits can be modified the same way to fit smaller JIS screws. Pictures 2 and 3 below shows DeWalt #2 and #3 modified bits.

I did find a place that sells authentic JIS bits. They don't list the #3 bit, but if you contact them they can provide the #3 JIS bits even though they are not listed on the website. These folks were very easy to work with, and the authentic bits do work great. Here's their site:

www.rjrcooltools.com/shop_item_detail.cfm?subcat_ID=89

Pictures 4 & 5 below show a comparison between my home made modified bits with the authentic JIS bits.

PICTURE 1


PICTURE 2


PICTURE 3


PICTURE 4


PICTURE 5


Before reaching for that wrench or ratchet consider the following. The bolts are steel, but your engine and front forks are aluminum. The bolts are much tougher than the aluminum and if over tightened will strip the aluminum threads. Although these can be repaired, preventing damage by applying proper torque will save you grief, time, and money. Tightening fasteners properly requires torque wrenches. Various vendors, including Snap-on, CDI, Sears, etc., market torque wrenches. The two most popular types are the bar type and micrometer type. Either will work, but the micrometer type is a bit easier to use, especially if you are tightening several fasteners with the same torque - such as cylinder head covers. You will need a torque wrench calibrated in INCH POUNDS for many of the bolts. You will also need a torque wrench calibrated in FOOT POUNDS for the larger bolts. Don't try to use the foot pounds wrench on the smaller bolts as it will not be sensitive enough at low torque settings to provide accurate torque. There are many fasteners that require low torque. These include such things as 6mm oil pan bolts, cylinder head cover bolts, etc. for which the torque in 61-78 inch pounds. These low torque bolts require a wrench that is accurate at low settings and this wrench should be graduated in inch pounds. In addition, there are numerous high torque fasteners such as the front axle nuts (51 - 65 foot pounds) or swing arm pivot shaft nuts (58 - 87 foot pounds). These require a wrench that is accurate at higher settings; this wrench should be graduated in foot pounds. Using the proper torque wrenches to correctly tighten fasteners will help prevent damage and contribute to a safe bike. The Kawasaki Service Manual will list the various torque specs for the bolts. I suggest you get the manual before buying the torque wrenches so you can decide which wrenches best meet the torque specs.

Consider buying a can of Kroil penetrating oil and use it to soak stubborn fasteners for a couple days before trying to loosen them. Remember, the original screws and bolts were installed on your bike when Jimmy Carter was President, so many of them may be hard to remove. Kroil can be bought online, at guns shows, and at some other venues.


MOTOR OIL
The ingredients in oils have changed over the years. For example, today's Castrol GTX (and pretty much all AUTOMOBILE oil) is not the same as it was in the 1980's. Back then it worked great in KZ bikes, but things have changed. Zinc and phosphorus additives (ZDDP), important to protect engine components from metal to metal contact, has been reduced since it’s been found to shorten catalytic converter life. Today’s auto oils contain about ½ the ZDDP they used to and different additives have been developed as substitutes. Unfortunately, some of these newer additives, in particular molybdenum disulfide, don’t get along with the wet clutches in our bikes. Newer oils, especially those labeled “Energy Conserving” (EC), which have a high quantity of friction reducing additives, should be avoided. These oils work fine in automobiles but there are better choices for motorcycles.

KZ bikes need oil which is suitable for wet clutches. That distinction was defined by the Japanese Engine Oil Standards Implementation Panel (JASO), and can be noted by oils that meet the "4T” (4 cycle) specification, MA (wet clutch) classification. These oils, which include various synthetic, semi-synthetic, and non-synthetic oils, are sold as specific motorcycle oils. Another type of oil which works well in our bikes is diesel engine oil. These oils are governed by the API (American Petroleum Institute) CI-4/CJ-4 spec and don’t contain clutch-damaging EC additives. You can even purchase Shell Rotella oil which holds a “JASO-MA” certification assuring it will get along well with your wet clutch. All of these newer oils have a reduced ZDDP level too (about 1/3 less than before instead of ½ like the auto oils) but the substitute additives get along better with our bikes needs than automotive oil. Oils that do not hold the JASO-MA rating have either failed the wet clutch test or have not been tested for use in engines with wet clutches. Good luck with the bike! Ed

I found this 1986 GPZ550 for sale and couldn’t pass it up. It compliments my 1980 KZ550 the first year of the 550 motor since the 1986 is the final year of the 550. Plus it was in excellent condition and only had 10,300 km. The PO kept it garage stored for the past 8 years and only started it up every once in a while but didn’t really ride it, apparently the same with the previous PO. The bike started, motor ran great, everything appeared to work. I am calling it a renewal since I don't have much restoration to do.

I plan on changing oil, oil filter, air filter, replace brake fluid, fork oil
Lubricate swing arm pivot, uni-track linkage, steering stem, cables, speedometer gear, wheel bearings
I will check the valve clearances
Pulled the spark plugs and they appear good but cheap to replace
The chain looks ok and is within tolerance 317mm and sprockets look ok
The headlight glass has a chip in it and needs replacement
The right signal lights were not working and I traced the problem to where the wire split at the headstock to go to the indicator and the signal light
The Bridgestone tires F-100/90-18 R-120/80-18 are old and have cracks and will be replaced probably Bridgestone or Pirelli same size

KZ Forum Members Advice Needed
Due to the age of the bike the manual says replace the brake hoses, anti-dive brake plunger assembly, master caliper cup and dust seal, caliper piston seal and dust seal. I know the bike is 30 years old but the forks and brake calipers look good and work great and to replace all this will cost $250 so I am thinking of leaving them as is. Even the disc brake pads appear to still have lots of material left and at $35 a set I am thinking of not replacing them until the wear requires it. I would appreciate any advice from members on these items.




Thanks