Saving a '81 KZ750-E

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01 Oct 2020 13:59 #835987 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Back at it after a trip to the east coast for a week. Before I left, I applied the Permatex Liquid Metal filler so it would have plenty of cure time. I tried sanding it down today and did not get very good results. I am altering my application method since this stuff starts to harden very quickly when exposed to air. It is a thinner liquid than I was expecting, but cures really quickly. After cleaning the entire surface, I started to fill and smooth small areas at a time. This looks like it will sand down much smoother. I will give it another day or two and try another sanding. I am going to use a finer grit paper this time around as well.

I was glad to hear two of my part shipments won't arrive until tomorrow. I was afraid they would be left on the porch while I was out of town. I asked a neighbor to keep an eye out, but the tracking is saying delivery tomorrow.

The clutch inspection revealed all the parts are in very good shape, and well within service limits. I had expected this to be the case, actually. Knowing the original owner, and how easy he rode this bike (not a racer type, more of a commuter and cruiser) I didn't think the clutch would have excessive wear. A new roller bearing, and lock nut for the clutch hub are on the way. Parts are clean and waiting for the rest of the parts. I should have the bottom end back in the frame inside of the next week.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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01 Oct 2020 16:05 #835997 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
The second attempt yielded much better results!


Another cleaning and I should be ready to paint.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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01 Oct 2020 18:52 #836007 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I didn't catch all of the pits, but I got the majority of them. I'm happy with the results this time. Three coats on, the site glass will get replaced in two or three days.


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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02 Oct 2020 14:46 #836054 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
The piston ring compressors showed up. Should get one more package before the end of the day.


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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02 Oct 2020 16:45 #836065 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
First look with the new SS case hardware. Perfect amount of bling, if I do say so myself!


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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02 Oct 2020 16:49 #836066 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
More stuff showed up!


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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02 Oct 2020 19:08 #836070 by Mikaw
Replied by Mikaw on topic Saving a '81 KZ750-E
Mikey likey

1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.

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02 Oct 2020 19:50 #836071 by Dr. Gamma
Replied by Dr. Gamma on topic Saving a '81 KZ750-E
I have a feeling your ring compressors are not going to work out. Don't think you will have the room to use them. If you don't have the fancy Kawasaki ring compressor tool, you do two pistons at a time.

Here are two photos of the Suzuki ring compressor tools being used on some 73mm Kz1000 pistons. You do the two center pistons first, then do the two outer pistons when you use this type of ring compressors. It took me like 2 or 3 tries to get the center two pistons into their bores. After that the outer two went in on first try!!!!

You might have to use something like these Suzuki ring compressors to get your pistons into their bores!!!




1972 H2 750 Cafe Racer built in 1974.
1976 KH400 Production Road Racer.
1979 Kz1000 MK. II Old AMA/WERA Superbike.
1986 RG500G 2 stroke terror.
1986 GSXR750RG The one with the clutch that rattles!

Up in the hills near Prescott, Az.
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02 Oct 2020 20:30 #836076 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I had the same concern in the back of my mind when I opened one up. The are a bit tall. Ah, well... another bridge to jump off of when I get there. As soon as the bearing and lock nut for the clutch hub get here I will be able to get the clutch and cover installed. Then the bottom end goes back in the frame.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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03 Oct 2020 10:33 #836105 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
The new hardware works well with blacked out case covers.


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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The following user(s) said Thank You: M_a_t_t

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05 Oct 2020 14:14 #836244 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Using some wood for support, and my wife's help, I got the bottom end back in the frame.


Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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The following user(s) said Thank You: M_a_t_t, Exactly

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05 Oct 2020 16:39 #836253 by Exactly
Replied by Exactly on topic Saving a '81 KZ750-E
This is amazing!
I wish I had the skill, exp, means and space!!
Cant wait till its done

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