Machining cases for bigger sleeves???

OK, I need help AGAIN!! Can anyone tell me if the cases can be machined WITHOUT taking them apart? I believe the studs need pulled out, but do the cases need to be split? Also, I had them bored before for a 1229 kit and was wondering if the cases would need bored again for a 1260 or 1327 kit?? Any help on this would be very appreciated. I want to go a little bigger this winter but don't really want to split the cases if I don't have to. Thanks!

Post edited by: 79MKII, at: 2005/12/18 20:12

anything beyond the stock sleeves requires boring the cases,and the do need to be split.goodluck,happywrenching!

Well, that's a bummer about needing the cases to be split, but I thought they probably would have to be. The other question is what about boring the same sleeves I already have? If I already have a 1229 kit installed with sleeves and cases bored to match, can the sleeves be bored without being replaced (and requiring a bigger bore in the cases too)? The guy that I had help me with the engine work has long since moved away.
Thanks

is the block stock,if it is the 1229 kit is at the max,(if not over) if its a big block you should be able to go out to 1260 with just boring.

check with the piston manufacturer they should be able to tell you which sleeves you need to use or if you can keep the same sleeves.if you can keep the same sleeves that will save you from splitting/boring your cases again!goodluck,happy wrenching!

If you've never split the cases on a Z1/KZ900/KZ1000 you will be surprised how easy it is.

should we let them know that kawasaki gives you all those neat bolts on differant parts of the bike to use as tools to take the engine apart?

Well, if I remember correctly, the stock block was resleeved to accept the 1229 kit. I've disassembled / reassembled the jugs and cylinder head several times, and had the motor in and out of the fram, but I have not split the cases myself. I had someone do the bottom end work for me the last time (gears undercut, crank welded, etc...). Maybe it's time to learn this winter??

Splitting and putting the cases together is pretty simple. I found the most difficult part to be getting the shift rod stuff assembled correctly, after the cases were back together. Seemed to me that everything inside the cases fits together without any room for error.

I kow Wiseco catalog is good about what work needs to be done and limitations of stock liners, blocks and cases. Yeah, pretty simple job. Shifter forks are a bit of an issue. I would place more attention on oil pump drive gear and make sure oil pump is full and primed when reassembling. Also internal o-ring between case halfs.

Here goes.. If it has a stock block, it should have 3.200 dia sleeves installed. This is the largest you can put in the stock block and not have oil leaks. The 1260 sleeve is 3.275 Dia. Some have put those in stock blocks and went to great pains to make them not leak. The 1327 thru 1428 sleeve is 3.450" and requires a big block.

As you can see, these would be three different case bore sizes. Yes the cases nave to be split, studs removed, and the empty case bored. We use a special fixture to make sure the bored holes are in the right location.

More sleeve info here;
kzzone.com/blocks.html

Jay