KZ1000A1 Spare Parts Project

Mikaw: The pistons were pretty cheap, but I want to stick with standard compression on this build. I did consider the IMD 71mm kit but that has higher compression as well.

Wookie58: Yeah, it was on the frame when I got it. Seems like this thing took a bit of a hit! 

Nothing wrong with a little bit of compression Calum, these old bikes love it. Those IMD pistons haven't got much of a dome, they be lucky to much more than stock compression...

You're right, I think I got them confused with some other pistons as they are a direct replacement. I have a set of OE +0.5 pistons that are in good shape and only cost me €120. I think I'll probably go for some IMD rings.

Been pretty busy and haven't updated this in a while. Got the clocks sent off to get calibrated and have the damping fluid renewed. Started work on the engine today. Cylinders and head are with a local guy getting sorted, but am starting to get the bottom end together.
Sorry for the bad lighting on the first couple of photos.

 

 

 


Haven't got a decent lock washer for the kickstarter stopper so used spring washers and loc-tite. Had to take them out again as the left screw in the picture sat up too high and touched the bottom case. Don't want to pay $30-40 getting a lock washer sent from the States (can't find any in Europe) so I'll get some standard DIN 463 ones and see how they fit.

 

Haven't got a decent lock washer for the kickstarter stopper so used spring washers and loc-tite. Had to take them out again as the left screw in the picture sat up too high and touched the bottom case. Don't want to pay $30-40 getting a lock washer sent from the States (can't find any in Europe) so I'll get some standard DIN 463 ones and see how they fit.

Could you use lower profile bolts with out the spring washers but with the "loc-tite" then drill and lockwire them ?

 

Got the lock washers today and used them with some loctite - there's enough clearance for the kick-starter so I'll just stick with them. The 79 and on models just use loctite - so I guess they deemed the lock washer unnecessary.

 

Back together and going in the frame tomorrow. Not completely done but I can finish it off in the frame - need the bench for the next engine...

 

That is super clean, hope you wear gloves when you touch it 

wrote:

That is super clean, hope you wear gloves when you touch it 

Two pairs

Bottom end is back in the frame. Clutch isn't reassembled but I wanted to see how my dodgy polishing job on the cover turned out - OK as long as it's not in the sun

 

Got some pics back from the engine guy. Will only cost about €100-150 to get the cracks fixed so I'll get it done just for peace of mind. He grinds out the crack with a dremel, gets it laser welded and then uses the remainder of the threads to tap the weld. 

 

 

 

 

Thats a decent price for the job and like you said "for the peace of mind" but also that camera he has.. wow i thought he was going to zoom into the molecules next.