Testarossa's 78 KZ1000 Fighter Build

wireman wrote: show off! :laugh:

Hey, I'm not showing off. This is my application for the new machine shop foreman at Zmax!

the "press" in my milwaukee cordless drill press comes from me pushing on it! :sick: :woohoo:
hopefully ill here something back tomorrow about the building down the street,then ill have some room to spread out and buy some bigger tools for shop.

Nice work Josh! Thats what I like some real detailed work keep them pics coming.

Yikes! :ohmy: Those pilot jets were stuck in there really tight! :pinch:

Kudos for a job well done on removing them.

Just curious as to whether it might be beneficial to "heat" the jet block and "freeze" the new brass insert immediately before putting them together, with a view toward eliminating the need for any pressure (akin to method for bearing fitment).

Once assembly is completed and temperatures normalize to tighten the fit, they should remain tight during service where temperature of both remains equal.

No doubt you will soon deserve your very own parking spot. :lol:

Good Fortune!

Well , i guess u can do it that way.


i would have just done it with my grinder. lol

Marks fingers after cutting his nails with his grinder:

:ohmy: :laugh: :woohoo: :woohoo: :woohoo:

Patton, you are right in that it would be marginally easier to install the inserts if I had done the freeze one, heat one trick. However, if I had made the insert too big and the temperature normalized, then it could have split the boss on the thread block. This method allows some "feel" so I could abort if I felt that I was going to crack the aluminum. Now I wouldn't necessarily suggest this repair for just about anybody. I have a lot of experience assembling thin walled aluminum parts, and have learned the hard way what will give and what won't. That jet block is a very fragile aluminum part. I was surprised at the amount of porosity in the aluminum when I milled out the threads.

It really didn't require that much force to install that insert. It's a very small vice that I used to press it in with. I was able to press it in with only finger pressure on the small vice handle. Here's a picture of the vice that I used:



The vice is only 2 3/8" wide and maybe 6" long.

oh yeah!







way to go josh.

you saved some carbs that probably did not have much of a chance any where else.

so now when you are done with them there will be no doubt in your mind that they are right.

very inspiring.

leon

p.s. this is awesome,i get my kz fix and
MACHINING PORN!!

Well I wasn't able to get to the mill today so I had to settle for getting the nasty Heli-coil out from the one jet block and I stripped the black paint from the caps and started to polish them. I started by sandblasting off the black paint:



Then sanded them starting with 80 grit since there were some heavy scratches under that paint. Then 180, 240, and finally 600 grit before I hit it with some rouge on buffing wheel.



I got the new pilot jets, needle jets, and jet needles today from Z1E. Thanks again Jeff! I shold have these carbs back to life in short order.

Looking good bro.

Agh ha ha ha ha hah ahahah ah ah ahah ha hhhahhh. I finally got it. Finally figured it out. I can't believe it. Ha ha hah ah ahahahahaha! :lol: :lol: :lol:

What an idiot I have been! Hahahahahaah! :woohoo: :woohoo: :woohoo:

That stupid vibration. I finally got it. Sometimes revving your bike like an idiot is useful. After I finished changing the oil, I started the bike and was listening all over the place for that stupid vibration and I found it. The damned license plate. Hahahaha! I never bolted down the lower two holes in the license plate, and it was vibrating against the aluminum backing plate. How dumb is that? Been sweating that little vibration for two months now.

Had to take the exhaust off to get the oil filter out. Gained an exhaust leak for my efforts, and I could care less. Guess I need some new exhaust gaskets.