Saving a '81 KZ750-E

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05 Oct 2020 17:16 #836256 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E

Dr. Gamma wrote: 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.


You are certainly correct, Dr. Gamma... it turns out these are the type for putting in the pistons from the top of the cylinder, not the bottom. But that brought me to an idea. If I was to make a couple spacers to hold the cylinder block at the right height off the case, couldn't I install one piston at a time from the top, going from one side to the other while preventing the crank from turning. I guess it might be a pain to control the rotation of the piston to line up with the rod... I have arranged for the return of these compressors already, I was just mulling over if it could work going from the top down.

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

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05 Oct 2020 19:45 #836265 by Mikaw
Replied by Mikaw on topic Saving a '81 KZ750-E

Skidmark wrote:

Dr. Gamma wrote: 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.


You are certainly correct, Dr. Gamma... it turns out these are the type for putting in the pistons from the top of the cylinder, not the bottom. But that brought me to an idea. If I was to make a couple spacers to hold the cylinder block at the right height off the case, couldn't I install one piston at a time from the top, going from one side to the other while preventing the crank from turning. I guess it might be a pain to control the rotation of the piston to line up with the rod... I have arranged for the return of these compressors already, I was just mulling over if it could work going from the top down.


When I saw your ring compressors I was thinking the same kind of thing. If you could hold the jug up and install each piston from the top slid down to the spigot with the crank held steady and install the wrist pin and cir-clip. has anyone tried that...

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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05 Oct 2020 19:53 #836267 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
My race pistons came with teflon buttons instead of wrist pin clips. Should be a little easier?

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

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06 Oct 2020 15:38 #836307 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Not something to be proud about, but I am getting rather good at this crap... five new clutch bolts are on their way.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
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06 Oct 2020 16:58 #836315 by Mikaw
Replied by Mikaw on topic Saving a '81 KZ750-E

Skidmark wrote: Not something to be proud about, but I am getting rather good at this crap... five new clutch bolts are on their way.


Getting good at breaking them??? lol

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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06 Oct 2020 19:11 - 06 Oct 2020 19:11 #836320 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Yes, which leads to experience taking them out.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
Last edit: 06 Oct 2020 19:11 by Skidmark.

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06 Oct 2020 19:23 #836321 by Mikaw
Replied by Mikaw on topic Saving a '81 KZ750-E
Sunday I was heartbroken, I was going over the cases looking for any issues before I send them to vapor hone, and sure as Hattie's I find a a broken bolt in the upper case for the clutch cover. Threw it up on the bench and started to pick at it to see what I was up against... Whoo Hoo it just silicone. Dug most of it out and run a 6mx1.00 tap in and all set...

Sorry didn't mean to rub it in... carry on... 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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06 Oct 2020 19:33 #836322 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
If you wrench, it comes with the territory. Didn't take it as a rub at all.

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

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12 Oct 2020 13:28 #836717 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Seems like Partzilla is getting slower at shipping orders lately. Doing more waiting than building. :whistle:

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

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12 Oct 2020 19:26 #836738 by DOHC
Replied by DOHC on topic Saving a '81 KZ750-E

Skidmark wrote: Seems like Partzilla is getting slower at shipping orders lately.


Yes, I noticed the same thing. Hit or miss these days. But it is an odd time for everyone.

'78 Z1-R in blue , '78 Z1-R in black, '78 Z1-R in pieces
My dad's '74 Z1
'00 ZRX1100

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13 Oct 2020 13:24 #836789 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
Case Savers. I have been wrestling with this ever since I took this bike apart - use them or not? Since the original hardware and motor mount plate on the right front side are long gone, I was thinking of having them powder coated to match the frame. But the chrome plating is an issue. I cannot find anyone in Nevada or Sacramento that will strip chrome plating. The plating shops I have talked with can apply chrome, but will not strip it. Apparently the chemicals to strip the chrome plating are quite nasty and the government regulations in controlling them have forced the businesses to quit using them. Since bead blasting it off is too time consuming, I decided to run without the case savers. I had to order some new bolts and make the engine mount plate for the top right side.

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

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14 Oct 2020 11:51 #836853 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
How much do we love our KZ's? You find out when your bike starts to fall off the lift. Luckily it was lowered all the way when the two of us lost our balance, and it fell the same direction as I did. Since the bike landed on me there wasn't any damage to it. Me, on the other hand, well... mostly minor cuts and scrapes and will probably find some interesting bruises in the next day or two.

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