Saving a '81 KZ750-E

Another step forward - the clutch and side cover are assembled.

I am getting my cylinder head back from the machine shop today. Looking forward to seeing how the valve clearances come out!

I was gone for 5 days, back in the shop. After the valve stems were ground, here is where the clearances ended up...

Exhaust - new shim size 235 across all four valves

Intake - new shim size 235 on three, 240 on one

My numbers to grind off should have put me in the 250 range. All of them are around .005" short of what I asked for. I am impressed with his consistency, just not as much as his accuracy. I am going to run with it as it does leave some room for the wear in of the seats.

Over three weeks just to get a starter o-ring. Sheesh! And not coming from out of the country. Now that I know what shims I will be using, those will take another two weeks as well.

The o-ring arrived today, so I got the starter installed.



I started to fabricate the shift linkage. I will need to cut down the stock shifter to the right length and drill a hole so I can bolt the linkage up.

I also started to fit the chain in place for the first time, and as I was fearing it interferes with the swing arm gusset I made. I will need to pull the swing arm and clearance it. The chain looks like it won't need a huge amount of relief in the tube wall.

You can try to made a roller guide for the chain like PMC did.

My chain clearance issue is on the side of the chain. That set up looks like it would control the vertical clearance, not the horizontal. Thanks, though... I will post some pics of the interference to make it more clear.

Prime Video has several great documentaries on the 500cc GP races in the late 80's and early 90's.

Wayne - the story of Wayne Gardner's career
The Unrideables - details the rise of the 500cc GP bikes
The Unrideables 2 - The career of Wayne Rainey

I just watched all three of these movies. Brings back great memories as my wife and I attended all but one of the GP races at Laguna Seca. There is also another one detailing the career of Kenny Roberts, but I don't recall the name of it. What an amazing time of motorcycle racing!

The Unrideables videos are great!!! I love their comments about trying to hold on to a 500cc two stroke GP bike!!!! I can still picture Wayne Rainey crawling off the track after being spit off by one of those monsters. Those were the days of real Grand Prix road racing. These oil and gas separators of today's Moto GP bikes with all their electronic gizmos. Traction control, launch control, and oh yea anti-wheelie control. A monkey could most likely ride one and win. Besides Rossi, I don't think any of today's Moto GP riders could even ride an vintage 500cc two stroke GP bike. NONE OF THEM!!!!!

Be glad you got to watch the 500cc two strokes at Laguna Seca. In my book those were the heydays of Grand Prix motorcycle racing!!!!!!!

REAL MEN RODE 500cc GRAND PRIX.

My first trip to the GP races at Laguna Seca I got to watch Kenny Roberts race. Amazing!! The infield section wasn't built yet. After turn two there was a straight leading up the hill to what is now turn five. Kenny and Randy Mamola would wheelie all the way, putting on a show for the crowd. I saw the upcoming of Freddie Spencer, and Kevin Schwantz. I even named my son Kevin! Good times... good times.

Just a small miscalculation on my part. The fix may be a lot more involved than first thought...