Need Advice.....Badly

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15 Jun 2012 22:01 #529440 by NakedFun
Need Advice.....Badly was created by NakedFun
Ok, so I got my KZ stem out unharmed and it is ready to press into my ZRX lower triple that had the bushing made and pressed into the triple, ready to accept the KZ stem......I pressed it in by hand!!

Dang. So whomever made the bushing doesn't understand what an interference fit means. So looking at the bushing, it appears to have been red loctited in place, which will make getting it back out even more fun. So the question is, what now?

1. It is about a .001" over size compared to the OD of the stem. Thought about welding to the bottom of the shaft, then having it ground down, but over size.

2. Somehow get that stupid bushing out and have a new one made. Probable a PITA.

3. Use red loctite between the stem and the bushing and push them back together?

Any other options? Unfortunately the bushing was made of aluminum, so no welding the bushing to the stem with this one.

Set backs like this suck......sorry for the language.

Cory

2008 Kawasaki Concours 14
1999 Kawasaki ZRX1100
1976 Kawasaki KZ900

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15 Jun 2012 23:13 #529462 by wireman
Replied by wireman on topic Need Advice.....Badly
Id figure out how to yank it out of there and have one made from steel B)

posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.

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15 Jun 2012 23:45 #529478 by NakedFun
Replied by NakedFun on topic Need Advice.....Badly
Yeah I am afraid it will come to that. The ZRX triple tree bore is 29 mm so the bushing takes it down to 28 mm OD which is pretty thin.

Cory

2008 Kawasaki Concours 14
1999 Kawasaki ZRX1100
1976 Kawasaki KZ900

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15 Jun 2012 23:47 #529481 by MFolks
Replied by MFolks on topic Need Advice.....Badly
Heat will soften up red loctite, but be careful around other items that may burn/melt. 300-350F should loose up it's grip. Let's hope the former owner didn't use the type that needs 450F to loosen up.

1982 GPZ1100 B2
General Dynamics/Convair 1983-1993
GLCM BGM-109 Tomahawk, AGM-129A Advanced Cruise Missile (ACM)

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15 Jun 2012 23:50 #529483 by wireman
Replied by wireman on topic Need Advice.....Badly

NakedFun wrote: Yeah I am afraid it will come to that. The ZRX triple tree bore is 29 mm so the bushing takes it down to 28 mm OD which is pretty thin.

Cory

Is there room to open triple tree up for thicker bushing? B)

posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.

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16 Jun 2012 00:44 #529497 by NakedFun
Replied by NakedFun on topic Need Advice.....Badly
Yeah, so looking at this again, I took multiple, precision (I have the equipment...) measurement around the diameter of the bushing, stem, and original KZ triple tree stem hole. Here is what I am getting for averages of each measurement point.

Stem Diameter: M1 - 28.05 mm , M2 - 28.06 mm , M3 - 28.03 mm
Bushing: M1 - 28.08 mm , M2 - 28.07 mm , M3 - 28.07 mm
KZ Triple: M1 - 28.12 mm , M2 - 28.17 mm , M3 - 28.09 mm

The KZ triple had the greatest measurement deviances, but since they welded it in, I would assume their machining tolerance they were holding to was not required critical.

If you look at the three measurement points between the bushing and the stem you get a delta of:

M1 - 0.03mm (0.001") , M2 - 0.01mm (>0.000") , M3 - 0.04mm (0.0015")

That is pretty dang close. I am seriously considering knurling or stiffling the OD of the stem and then using a Loctite bearing compound such as 648 or 680 which is said to aid slip fit retaining to a sheer of 3800-4000 psi.

This in conjunction with the retaining steps in the shaft at would prevent downward movement, and the clamping force of each tree to fork, I feel this would be a pretty safe bet that it would never become a problem.

Cory

2008 Kawasaki Concours 14
1999 Kawasaki ZRX1100
1976 Kawasaki KZ900

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16 Jun 2012 00:46 #529498 by NakedFun
Replied by NakedFun on topic Need Advice.....Badly

MFolks wrote: Heat will soften up red loctite, but be careful around other items that may burn/melt. 300-350F should loose up it's grip. Let's hope the former owner didn't use the type that needs 450F to loosen up.


Could always throw it in the oven for a 15 mins prior to dis assembly. Would be a PITA to handle while that hot.... lol

Cory

2008 Kawasaki Concours 14
1999 Kawasaki ZRX1100
1976 Kawasaki KZ900

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16 Jun 2012 12:17 #529570 by Mark Wing
Replied by Mark Wing on topic Need Advice.....Badly
After I pushed my stem in on my set up for safety i drilled the tree and stem and put in a pin through them to hold as a safety.
Mark

Jesus loves you Everyone else thinks your an ***

77 KZ650 C1 with ZX7 forks, GPZ mono rear, wider 18 police wheels and Yoshimura motor.

Yorba Linda Cal.
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16 Jun 2012 17:50 #529634 by Tomolu5
Replied by Tomolu5 on topic Need Advice.....Badly
I would seriously think about knurling the stem, then use the loctite. And use the safety pin idea. Is it possible to weld a nut inside the bottom of the stem (or drill and tap if its solid) then run a bolt in from bottom of tree?

Mine:
04 Honda rebel 250(wifes)
04 GSXR 750(bolt on galore)
98 CBR 600F3(filter, pipe, adjustable cam sprokets, dyno tune)
76 KZ900A (LTD gauge pods, crash bars, LTD(style)pipes, dyna coils and ignition,headwork and mild port cleanup by cavanaugh racing, K&N filter pods, heck I dunno.

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16 Jun 2012 19:50 #529681 by NakedFun
Replied by NakedFun on topic Need Advice.....Badly
Yeah I am going to get a couple opinions from some machinists I know at work. I may just have a steel bushing made and weld the shaft to it. The knurling and loctite would probable be more than enough, and the thought had crossed my mind about having a bolt come up from the bottom. It just seems like if I am going to go that far, just have a new bushing made and be done with it.

Cory

2008 Kawasaki Concours 14
1999 Kawasaki ZRX1100
1976 Kawasaki KZ900

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16 Jun 2012 23:10 #529713 by Tomolu5
Replied by Tomolu5 on topic Need Advice.....Badly
To be honest I would probly overkill it with the bolt anyhow. I do realize it would be overkill though.

Mine:
04 Honda rebel 250(wifes)
04 GSXR 750(bolt on galore)
98 CBR 600F3(filter, pipe, adjustable cam sprokets, dyno tune)
76 KZ900A (LTD gauge pods, crash bars, LTD(style)pipes, dyna coils and ignition,headwork and mild port cleanup by cavanaugh racing, K&N filter pods, heck I dunno.

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17 Jun 2012 01:07 #529749 by NakedFun
Replied by NakedFun on topic Need Advice.....Badly
Well I am going to weld the shaft and turn
It down on the lathe tomorrow in order to get the press fit I want.

Cory

2008 Kawasaki Concours 14
1999 Kawasaki ZRX1100
1976 Kawasaki KZ900

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