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TOPIC: My first engine rebuild on a 1980 KZ1000 LTD

My first engine rebuild on a 1980 KZ1000 LTD 3 years 6 months ago #451984

  • DoctoRot
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After finding out that my beloved KZ1000 had some top end damage and poor compression, I was coerced into rebuilding the engine myself. I have never attempted anything like this before.

So far, I was able to pull the engine out of the frame, and I started tearing it down, There is ALOT of carbon build up in the engine, I have been cleaning it out with some engine cleaner spray and a toothbrush, but it is slow going.

I am a firm believer that if you are going to do something, do it right. That in mind, I want to replace as many parts that see wear as possible, I don't really know where to start on ordering parts, I was hoping there was a engine rebuild kit that I could buy and would have everything I need in it, but i haven't been able to find one. Anyone know of a kit that out there, or what parts I should replace? I'm also not opposed to doing some mild performance upgrades on this either. any advice is appreciated

-vic
-Vic
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 6 months ago #451989

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Good for you Vic. Nothing will feel more satisfying that riding the old girl after a fresh build.

Do yourself the best favor and download/purchase an oem service manual, as well as a clymer manual. Both are extremely helpful step by step books of gold for newbies.

With the instructions included in these books, you will know exactly what to inspect, replace, restore, etc. and also exactly what tools to acquire.

Best of luck!

B)
Motorcycle Shop Owner/Operator

79 Kawie Z1000 LTD
81 Kawie Z1000 CSR
83 Honda VT750C A
85 Kawie GPZ900 A2
86 Zukie GS1150 EG
93 Yamie XV1100 E
Lucky to have rolled many old bikes through my doors ;)
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 6 months ago #451999

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take some pictures and give close ups of the valve faces and top of combustion area....cylinder.sleeves...and anything you are finding and then give us some precise ideas on where you are at...a manual will walk you through and by measuring and inspection each item ,you will be directed tot the solution by the step by step,engine service and rebuild chapters....pictures with words might help folks to follow your path and guide you better


see this picture for an example of a good close up that shows an item

in this pic i am showing a clear shot of a section on the cam ...


cams1.JPG
1976 KZ900 A4 38 years and counting
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 6 months ago #452029

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the best thing to do is get it all stripped down and let everything soak for a couple days to loosen up the crud before trying to scrape too much of that old carbon off.
once you get the parts reasonably clean take your pistons and cylinder to somebody with the right tools to measure the bores and pistons to see if theyre close enough to spec for a re-ring job,or if its going to need a bore job and new pistons.
if youre going to rebuild it you might as well go ahead and tell yourself youre going to replace the cam chain and guides/rollers etc,that stuff gets deep into the motor and its no fun to do twice.
good news is these motors have a pretty stout bottem end that generally doesnt need much more than a good cleaning and inspection B)
posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 6 months ago #452794

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be very very very very carefull when you tighten them cam cap bolts very easy to strip... i mean very easy to strip!!!!!!!!!!!!!!!!!!
hello, i own a 1982 kz1000 j model with a 4into1 header and factory air box...
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 6 months ago #452838

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And cams can break if not tightened down correctly. follow procedures the first couple of times you do this.

It is just a bunch of bells and whistles on one level. But screw one up and the rest will wait 'til you get yourself out of a bind.

Ask questions shamelessly! I do...
77 KZ 650 C1.
77 KZ 650 C1.
Crashed-Repaired, Pods, Kerker pipe, re-wired core bundle, lamp upgraded, homemade rectifier, solid state regulator , Dyna-s ignition, repainted, slightly modified, year-round commuter
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454207

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Just finished up another project so this baby can get all my attention. Also finally got my camera fixed so i could get some photos on here.


as you can see, its seen better days.












most of the rubber on the cam chain guides and sprockets are cracking off or very worn

The cams have some wear on the corners. particularly on cylinder one exhaust and intake. I need to go pick up a micrometer so I can start measuring the tolerances on them.


I took the cylinder off and tried to remove the pistons. I got the circlips out but the wrist pin doesn't want to come out. The manual said to try heating up with a torch, that didn't work either, it also has a diagram for a home made puller. I'm gonna try and make it today and see if i can get those pins out.

I started to take apart the head, but the first thing it says to do in the manual is use your valve spring compressor tool. I checked on Z1 and its $190! Is there anyway to remove the valves without this tool?
-Vic
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Last Edit: 3 years 5 months ago by DoctoRot.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454208

  • ELCouz
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Is there a way to remove the valves without having to buy the valve spring compressor tool? Id rather not drop $190 on it.

You can always take it to a engine shop... they charge a few bucks per valves (mine is around 4$)


regards,
laurent
1982 KZ810-R1 GPZ with hindle 4-into-1 pipe
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454211

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that's a great idea. Ill get on that tomorrow. also here are some close ups of the valves. There is alot of crud built up on there!

-Vic
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454228

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DoctoRot wrote:
...valve spring compressor tool...its $190! Is there anyway to remove the valves without this tool?

A diy tool is relatively easy to make from a large C-clamp, plus a fitting made of pipe (steel, aluminum or PVC), or an old wrench socket (you do the sculpture).

Here's a KZr thread with some detailed info about this diy tool.
kzrider.com/forum/2-engine/197012-valve-spring-compressor

Here are some other illustrations:

diyvalvespringcompressor1.jpg


diyValveSpringCompressorwelded.jpg


Good Fortune! :)
Last Edit: 3 years 5 months ago by Patton.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454300

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if you have access to a drill press it can be used in place of c-clamp using same kind of modified socket
posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454301

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DoctoRot wrote:
Just finished up another project so this baby can get all my attention. Also finally got my camera fixed so i could get some photos on here.


as you can see, its seen better days.












most of the rubber on the cam chain guides and sprockets are cracking off or very worn

The cams have some wear on the corners. particularly on cylinder one exhaust and intake. I need to go pick up a micrometer so I can start measuring the tolerances on them.


I took the cylinder off and tried to remove the pistons. I got the circlips out but the wrist pin doesn't want to come out. The manual said to try heating up with a torch, that didn't work either, it also has a diagram for a home made puller. I'm gonna try and make it today and see if i can get those pins out.

I started to take apart the head, but the first thing it says to do in the manual is use your valve spring compressor tool. I checked on Z1 and its $190! Is there anyway to remove the valves without this tool?
im more concerned about the grooves in bearing journals on cam,looks like shes missed some oil changes in the past B)
posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454831

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I was curious if those rings were normal, there seem to be alot of brown rings on different parts. Is that because I wasn't changing the oil frequently enough? I was changing it around every 2000 miles regularly, but near the end it was burning oil like crazy, so maybe it wasn't frequently enough.











Got the pistons off, and finished dissembling the rest of the engine.
went pretty smooth, except for one of the engine case bolts shearing off. there was a ton of corrosion on it for some reason



I also picked up this



and these



So now I will be cleaning everything up, and measuring the tolerances described in my Clymer manual. Ill be posting alot of close ups on here once everything is tidy so i can get some idea of what i need to replace.
-Vic
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KZ650B2
KZ750E1
Last Edit: 3 years 5 months ago by DoctoRot.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454847

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just beng finshed with my own rebuild on my 83 Kz 750 one of the things that id do diffrently for sure is

go ahead and glass bead blast ALL the carbon off the combustion chamber,

just get 80 grit blasting media and go at it.

all u have to do is stop as soon as the black comes off

this is doubly true for the valves, i started with a brass brush just like u did and very quickly discovered that was a task for an entire other life.

i just used metal tape around the flat rim of the head when i blasted it with the valves still in and it was short, quick, and sexxy finish. just lap ur valves good after and ur golden

BEAD BLAST TEH SHEET AND BEE DONE! B)
1983 KZ 750 shaft
2002 ZRX 1200R
Raleigh NC
Last Edit: 3 years 5 months ago by Treewizard. Reason: kZ
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #454898

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Treewizard wrote:
just beng finshed with my own rebuild on my 83 Kz 750 one of the things that id do diffrently for sure is

go ahead and glass bead blast ALL the carbon off the combustion chamber,

just get 80 grit blasting media and go at it.

all u have to do is stop as soon as the black comes off

this is doubly true for the valves, i started with a brass brush just like u did and very quickly discovered that was a task for an entire other life.

i just used metal tape around the flat rim of the head when i blasted it with the valves still in and it was short, quick, and sexxy finish. just lap ur valves good after and ur golden

BEAD BLAST TEH SHEET AND BEE DONE! B)
i think id be inclined to have the head fully stripped and stick a golf tee into both ends of each valve guide when blasting.
after you get done blasting head id take the cleaned valves and stick them in guides and give the rock test,if they move at all in the guides its time for new guides.
lapping valves on an old motor does little good in my experiance anyway.
you need a good solid guide fit to keep valve square on its seat and a good valve job and new springs to seal things up.the little bit lapping valves without a good valve job first is lost as engine gets up to temp B)
posting from deep under a non-descript barn in an undisclosed location southwest of Omaha.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #455098

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Thanks for the link to that thread Patton, made up one of my own and got the valves out.



After inspecting the valves I am definitely going to need new exhaust valves at the least, maybe intake valves as well. Also there is lateral movement on every valve guide, so I will be needing new guides as well. It says in my Clymer manual that I should have a shop instal new guides. I was looking at Cavanaugh Racing Heads webpage, and they offer a "Street Port With Valve Job - 20% Avg. flow gain. Nice performance boost for street and touring type riding with Drop In Cams." Thinking about springing for this. I'm gonna try to give them a call tomorrow to find out more.

Oh, and yeah, this happened.

-Vic
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #455108

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Brake cleaner works really good for cleaning off carbon, but you have to be careful on plastic since some plastics melt if it gets on them.
Kenny Hicks
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #455111

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Can't go wrong with any work done at Cavanaugh Racing . larry did an awesome job on my head for the 1200 im building . Good luck and good progress !
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #455733

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I
Last Edit: 3 years 5 months ago by jimmyjimmyjoe.
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My first engine rebuild on a 1980 KZ1000 LTD 3 years 5 months ago #455734

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use something soft like a brass drift and tap on it with a hammer to see if they move B)
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