Testarossa's 78 KZ1000 Fighter Build
- testarossa
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 20:47wireman wrote: show off! :laugh:
Hey, I'm not showing off. This is my application for the new machine shop foreman at Zmax!

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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- wireman
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 20:52
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.
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.

posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.
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- rslingshot
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 21:16
Nice work Josh! Thats what I like some real detailed work keep them pics coming.
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- Patton
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 21:21
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!
Kudos for a job well done on removing them.



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!

1973 Z1
KZ900 LTD
KZ900 LTD
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- mark1122
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 21:54
Well , i guess u can do it that way.
i would have just done it with my grinder. lol
i would have just done it with my grinder. lol

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.
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01 CBR600F4i Track bike.
Cobourg, Ont. Can.
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- T_Dub
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 22:09
1977 KZ650B1
-810cc
-Cavanaugh Racing Head
-Mikuni RS34's
-GPR Muffler
-810cc
-Cavanaugh Racing Head
-Mikuni RS34's
-GPR Muffler
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- mark1122
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 23:03 - 14 Apr 2011 23:04


Attachment 3d_clapping-49x56.gif not found
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.
~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
01 CBR600F4i Track bike.
Cobourg, Ont. Can.
~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
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Last edit: 14 Apr 2011 23:04 by mark1122.
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- testarossa
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Re: Testarossa's 78 KZ1000 Fighter Build
14 Apr 2011 23:06
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.
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:
Attachment vice.jpg not found
The vice is only 2 3/8" wide and maybe 6" long.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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- 531blackbanshee
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Re: Testarossa's 78 KZ1000 Fighter Build
15 Apr 2011 10:49 - 15 Apr 2011 10:51
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!!
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!!
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!
billybiltit.blogspot.com/
www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work
kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
1976 kz 900 x 3
i make what i can,and save the rest!
billybiltit.blogspot.com/
www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work
kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
Last edit: 15 Apr 2011 10:51 by 531blackbanshee.
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- testarossa
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Re: Testarossa's 78 KZ1000 Fighter Build
16 Apr 2011 00:51
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.
Attachment 0415010741.jpg not found
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.
Attachment 0415011118.jpg not found
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.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
Attachments:
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- mark1122
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Re: Testarossa's 78 KZ1000 Fighter Build
16 Apr 2011 11:48Attachment 3d_goodjob-51x36.gif not found
Looking good bro.
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.
~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
01 CBR600F4i Track bike.
Cobourg, Ont. Can.
~ ~ ~_@
~ ~ _- \,
~ (k) / (z)
Attachments:
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- testarossa
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Re: Testarossa's 78 KZ1000 Fighter Build
16 Apr 2011 18:43
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.
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.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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