TOPIC:

After spending a year pulling my 77 KZ1000 apart and rebuilding it from bending 2 exhaust valves, I thought I would post up my crazy low buck engine build for everyone to tear apart!

Here is a link to my build thread:

www.kzrider.com/forum/11-projects/260241...street-strip-project

Ok, lets see what we have here!

1015cc, stock KZ pistons & rings

removed base gasket

Self ported heads

Surfaced heads (just a cleanup of the head gasket surface, not a real milling job)

2 stock 77 kz1000 intake cams(factory exhaust cam swapped for a second intake cam)
NOTE: These will be running aprox. 2 degrees retarded due to the removed base gasket.

APE valvesprings

Mikuni RS34's currently jetted 120/17.5

V&H Sidewinder header, 2" shortened primaries, no baffle

A couple of things to keep in mind.

I know hand lapping valves is not the currently accepted practice for a proper valve job. I've done it before with good results, so I did it here.
I checked my piston to valve clearances and made sure the pistons did not come above deck. I did NOT degree the cams.
I know the cams will be retarded due to the removal of the base gasket. I am ok with that. This will increase top end horsepower and over rev slightly.
I did not go crazy with the porting. This is a small cc build but I knew there was power to be had in the heads. The valve bowls are so small stock! I followed the many DIY porting suggestion found in the forum from LarryC.

Why 2 intake cams?
There is not a lot to be gained with this..but it was apart and it was what I had available, so why not?
I would not pull apart an engine just to do this, but I was already here so it should net me a small gain up top.
It bolts right in, no special modifications required. I replaced the valve springs since I expected my 30 year old stockers where tired and contributed to the bent valves. Missing a shift didn't help either.
stock intake cam: 237@.040 0.327 lift
stock exhaust cam: 229@.040 0.296 lift

No base gasket:
Base gasket is .02...removing it puts the pistons at almost a perfect 0 deck height. I cleaned the block and cylinder and sealed it with a thin coat of good grey sealant. permatex/yama/honda/whateverbond. Be very careful not to get sealant in the oil passages! With the stock 34-35cc chambers and pistons, this will put me at 9.5-9.25:1 compression ratio. It was a gamble on my part, and it worked perfectly.

Its already been fired up and runs better than ever. Sealer in place of the base gasket does not leak at all, seems to have plenty of power.
It needs a little more main jet and a carb sync. Once that is all squared away I am going to try to get it on the local dyno, just for kicks. Even if it doesn't hit the dyno, the bike is destine for the dragstrip.

Any questions, let me know!

Some pictures, because everyone loves pictures!

Intake


exhaust


Old school valve job


Valves in


Double intake cams


Almost ready to go

First start:

Cool! My style also! Do what ya' can with what you got! Back Yard Engineering.
I don't know about the cams? But we did a project in the early 90's We Made a Diesel (1 cam) blower, nitro top fueler Kaw 4 cyl.

I see the orange O-rings in the bag. I just was looking at that same thing on eBay yesterday. They came with a set of factory valve seals.
They were pretty cheap? Right?

Glad it's running. Hate them old missed gears with the throttle wide open

No eBay APP ID and/or Cert ID defined in Kunena configurationSee the "OINK" guy has a set with some used valve guides.

Those are orings for the sleeves. Kawasaki stopped using them in later models, they came in the full gasket set I bought.

Is there something you need them for?

Hi Rev, no gaskets. I need a set of valve guide seals. Oink has a listing for $9.99. But once you bid, one of oinks gang bumps it up most of the time. I can get Viton seals from Paul Gast FBG for $2.00 a piece, He is 25 minutes from me. At cost. I don't like Viton for the long haul. plus I always got to buy 10, I always manage to rip a couple of them thin ones.
Thanks for the reply.

Why use Ape valve springs with stock cams?

Piece of mind. I've got APE springs with my stock ZX750A1 cams
and can hit the rev. limiter set at 11,000 easy.
And no I don't run it set there but have done it a time or two.

What are u using for a tachometer?

zukdave wrote: Piece of mind. I've got APE springs with my stock ZX750A1 cams
and can hit the rev. limiter set at 11,000 easy.
And no I don't run it set there but have done it a time or two.

Stiff springs put more wear on the parts compared to stock springs.

I've got about 10 miles on my new motor and 8 of them were at the drag strip
so I'll put up with a little more wear to keep the valve's from having sex with my new Wiseco pistons.

My motor rev's quick click on the pic.

zukdave wrote: I've got about 10 miles on my new motor and 8 of them were at the drag strip
so I'll put up with a little more wear to keep the valve's from having sex with my new Wiseco pistons.

My motor rev's quick click on the pic.

your bike soundds AMAZING!!!