KZ Cam Chain replacement

Hi all, so I have been fighting a noise in my engine that I have determined is my cam chain and guides being at the limit. So I puulled the head and cylinders for inspection and found the chain was indeed at the upper limit per the manual. This caused the noise because the tensioner was not able to take up the slack fully anymore. I considered replacing the guides and getting a manual tensioner but knew I would be merely putting off the inevitable. So,I figured I was so far in why not? Pull the engine, split the cases, inspect everything and reassemble. Last night I prepped the engine and tonight I removed it. Currently it is sitting on my cart with two of the side covers off. I willl now try to post some pictures. I will try to update as I go. Later, Keith

You won't regret it.
Steve

its its anything like a Z1B i'm doing for someone the front blade may well have been snapped off and sitting in the sump !

Only the top idler was halfway decent.

Steve, I am already happy that I am taking this step. I have done a lot of work to the bike but internals haven't been inspected prior to this. So, I have completed the disassembly down to the cases being split. Went very well. Better than I thought at least so far. The KZP is a different setup than the earlier models with the rollers. I was able to remove the side covers and leave everything intact as I took it apart. I mean it was like voodoo to me until today. So I took pictures with my 4 year old tablet yesterday and I couldn't send them anywhere due to the old operating system so I took some more tonight so here goes:

That was a test run. Here is the rest. Later, Keith

I put this many different ways. There is a certain security in knowing what's going on between your legs. When I grab a hand full, I don't worry about something coming apart.
Steve

I agree completely. I want to ride without worrying if I'm going to get home. Funny when I was 19yo I had a Honda 350 scrambler remember those? I don't remember ever doing any maintenance at all on it. Maybe I didn't have it long enough but really? I am 58yo and I am always looking at something. Weird huh?

My first real bike was a 71 CL 350. Had it three years. Took it everywhere, trails, out in the desert, rode along side Harleys, other bikes and the Z1's. Rebuilt it in my apartment (got evicted for that), learned how to wrench on bikes with it. Dropped a valve, blow outs, you name it. I bought Bossie in 75 and sold it to the Honda dealer in exchange for a seat. I still miss that bike. :dry:
Steve

Indeed 1st bike is always memorable. So, in true fashion I have decided to completely disassemble the engine and clean it up. I learned something today. Number 4 piston will not go thru the bore in the upper case. All the rest do. Found out the hard way. Got the crank partly out and couldn't remove it. All the books say remove the pistons first, now I know why. So I reseated the crank in the case and reinstalled the center bearing. Now I have to get a piston pin puller and remove them before I can go on. Other than that the disassembly was easy. Nown to clean and inspect once I get that crank out. Later, Keith

I made my own with some threaded stock nuts and a deep socket.


kzrider.com/forum/2-engine/597654-poser?start=80#690209
Steve

You should be able to push a floating piston pin out with not too much effort. With the circlip out, try warming the piston up with a hair dryer and tap the pin out.

Yes, thought about both methods and then chickened out. Figured I would somehow screw it up without a proper tool. With my track record of having to do things at least twice I wanted to reduce the risks of my work. So, I started to do some things that were bothering me since I finished last time. Sanding down the surface rust in those hard to get areas when the motor is in. Removed the battery box and am cleaning that up proper. Well, as usual I start to get the wiring out of the way and then I say might as well clean up the wiring too. Krikey, might as well rip it all apart. Not going to do that but it sure is hard not to. Anyway, things are looking good as I move forward. Can't seem to find the seat I really want so I am going to build my own. I will post some more pics soon for all to see. Later, Keith