1973 Z1 rebuild

Just for info we weighed the engine (minus heads/cams/starter/covers) before we dropped into the frame - 55 kg (121 pounds)
 

So I guess Zed1015's figure of 95KG for the complete unit is "bang on the money"  

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So I guess Zed1015's figure of 95KG for the complete unit is "bang on the money"  

 

I guess it depends on how "dressed" the engine is ?
The addition of head, cams, starter and engine covers wouldnt be another 40 kg ?

Well I have had a week away from the bike as we went away with friends for a week of eating and drinking too much.
But now its time to get back to it again.  I had to dig through all the box's of stuff to see exactly what I have because I have bought stuff and then found those parts in a box somewhere.  Found a bunch of original nuts, bolts etc and started a little collection to help with bolting things together as most bolts on the bike had been changed over to cap head (Allen) bolts.
The amount of time (and money) spent on nuts, bolts and washers on a project is often under estimated.
 
Next is getting the head back on, I cleaned up the surfaces and dropped the Cometic multi layer head gasket on, this gasket is embossed on both sides and is fitted dry.
 
I will be using a new set of washers, and put a slight smear of ARP lube on the underside of the APE head bolts to get a consistent torque application.
 
The cylinder head is dropped into place and the head bolts torqued down gradually to 25 ft/lbs.
The cam buckets are cleaned and lubed before dropping in and cam caps/bolts cleaned and test fitted.
 

This will be stunning when it's finished

Most people also under estimate the time needed to restore or rebuild a vintage bike.  I started a 650 as a winter project and am now almost two years into it.  I'm not disappointed though, just making an observation.

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Most people also under estimate the time needed to restore or rebuild a vintage bike.  I started a 650 as a winter project and am now almost two years into it.  I'm not disappointed though, just making an observation.

Ain’t that the truth, I am 4 months in and feel like I have barely scratched the surface 

Mine took 2-1/2 years before the first firing.  And it has been sitting a year waiting for me to get off my backside and synch the carbs.  Still hasn't been broken in... 

The Z owners are having a 50th anniversary display at a bike show on November 6 and I want to have the bike together by then, so it gives me a deadline to meet.  Doesnt matter if it isnt up and running properly, as long as it all together.
I spent some time today doing the front forks and triple tree.
The forks went back together with new inner and outer seals.  I cant find the original reflectors, I put them somewhere safe and Im just not sure where that is, so some spare replicas went on in the meantime.
The triple trees got greased up and ball bearings fitted.
It was tight trying to get the forks in, there was some powder coat in the holes that had to be sanded.
The new handlebars and bolts went on to top it all off
 

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The cylinder head is dropped into place and the head bolts torqued down gradually to 25 ft/lbs.
 

25ft/lbs is too loose and is the early figure which was amended in the later manuals.
Should be 28ft/lbs minimum and with stock studs you can go to 32 ft/lbs  .
You should go closer to the 32ft/lbs especially with the high comp pistons although those Cometic MLS gaskets are known to hold up even in turbo applications without the need for piano wired liners.

I try to bag everything with parts from each assembly in a separate bag.  I also try to keep everything in a bin.  But I still lose things!

Those front reflectors should have a black ring around the outside.  Kawasaki still sells originals.  You can get them from Partzilla.

wrote:

wrote:

The cylinder head is dropped into place and the head bolts torqued down gradually to 25 ft/lbs.

 

25ft/lbs is too loose and is the early figure which was amended in the later manuals.
Should be 28ft/lbs minimum and with stock studs you can go to 32 ft/lbs  .
You should go closer to the 32ft/lbs especially with the high comp pistons although those Cometic MLS gaskets are known to hold up even in turbo applications without the need for piano wired liners.

 

yes, Im thinking you are probably right - I had to click them again after 24 hours.
I will go up to 32 lbs and hopefully that should take up better.