Zukey Lake wrenchfest May 17th

Thank you to Dirk, Matt, and Mike for all your help this weekend. Looking forward to getting back together soon! 
 

You are keeping those boys busy Jim 

Quick update on our project 1974 Z1 900 engine build.  Case / thread repairs have been completed successfully.  Thanks to Matt "Mikaw" and Mike "Bogi1" for spending a good portion of their Saturday working on my engine case.  Looks like we will be trying to get together again in August to complete engine assembly!


 

Sounds like a plan 

Jim, you’re welcome. I’m learning a lot about the upper/lower cases by hands on in-depth investigation. AKA how deep can you drill and not break into the crankcase. Were the oil galleries run and making sure they dont get compromised. We drilled and taped for 12/ 10mm-1.50 helicoil by 25mm installed depth. Here’s where I need some help. Yesterday away from all my parts catalogs I researched the net looking for head stud length and position. Findings were all over the map. From Partzilla the four inner studs have two options 92004-1002 @10 x 190, and 92004-1004 @ 10 x 133. No way that can even be close to correct. See photo for part number 1 in this screenshot. Same for studs at location 3 of breakdown. Calling out the same options.

 

At mikes house we had studs that were about 190mm, 183mm, and 156mm, I called home and had my son measure studs I had just removed from a ‘76 Kz900 case and they confirmed we had the correct lengths in hand just no confirmation of correct placement. This morning consulting my parts catalog., I get some more backup and additional confusion. They call out the four center studs as 92004-045 @ 198mm. If you type in “Kawasaki 92004-045 into a search it brings up that number has been superseded by 92004-1002 @ 167mm. But if you refer back to my first screenshot and look up part 92004-1002 is says they are 190mm. HELP!!!
 
 
 

This is what CMNSL list for a 74 Z1 against the same diagram

 

Not sure this will be of any help but here is what Kawasaki.com indicates, just like the info you have found to date.

I don’t find any sizes from parts breakdown that make sense.

position  1.      192mm OA        164mm installed
              2.       183mm              150mm
              3.       159mm               129mm
there is approximately 30mm engagement into the upper case. None of the sizes called on in the parts fishe make sense. 

Ageed, how can there be two options for the same motor in the same position that are 34mm different in length ???????

Wookie58 wrote:

Ageed, how can there be two options for the same motor in the same position that are 34mm different in length ???????

It’s more, they are saying you have two length options for the same position 190mm or 133mm that 57mm difference. 133mm I thought might be the installed length but that’s actually 164mm. +-

Whether it's 34mm (CMNSL) or 64mm (Partzilla) I still don't understand how there can be "so much" length difference for the same location in the same motor !!! The installed length makes sense but then why two different part numbers !!! I would love to understand this as I am intrigued 

Agree this just does not make any sense. 57 mm (about 2.2 inches) difference in length. I too would like to know how this works.