TOPIC:

yessir,
i appreciate your taking the time to answer my questions.
thanks zed,keep up the good work.

leon

Very detailed, I love it. Very trick ignition, can't wait to see it come together.

Great job. i love the way u extended the fork length.
Well done.

Building this motor on a budget and just using up stuff i have lurking about so the inlet valves are std and have been trimmed along with the retainers etc to get max shim sizes back.
Plenty of graphogen on the buckets and valve lapping sucker is ideal for working it round the bores to get an even coating.



The std exhaust valves were quite battered and after recutting the seats and heads were borderline for trimming the retainers so a cunning plan was executed.
I had some 1mm oversize stainless valves from a customers bike that had very slightly wonky heads after his local bike shop ballsed up his engine rebuild.
So i chucked them up in the lathe and viola ! one set of std size stainless exhaust valves.

The head is now finished and bench shimmed so on with finishing the idler gears so i can fit it.
Sourced new roller bearings for the idler wheels i modified earlier.
simplybearings.co.uk/shop/p92295/BA78ZOH...ch/product_info.html
Strange how kawasaki opted for these in imperial when everything else is metric ?


Then on to my skinflint approach to a liska tensioner.
Left one is std z9/1000.
Middle is Z650 which has a bigger wheel . The black areas need removing to clear the barrel casting etc.
and right is modded Z650 item with idler sprocket.

zed,
on your rebuilt sprockets is it a solid alu.center or is there a steel bush in the center for the bearing bore?
in the pictures it looks like there is a steel center bush,maybe just a cutting oil stain .

i love your no holds barred method of bike building .

guide sprocket rubbers worn out,
no sweat just rebuild them with aluminum.

exhaust valves un-usable,
no sweat just cut down some intakes.

never say die man .

and a big up yours to anyone that didn't think you could .

keep up the good work sir.

leon

531blackbanshee wrote: zed,
on your rebuilt sprockets is it a solid alu.center or is there a steel bush in the center for the bearing bore?
in the pictures it looks like there is a steel center bush,maybe just a cutting oil stain .
leon

Hi, Well spotted.
Yes the center is steel.
It's the original idlers center with the bonded rubber removed.
I was gonna just bore the ally for the bearing but decided thet the steel would be less prone to wear during future bearing repacements.
Maybe a bit overkill but i don't like doing things twice.

[/quote]Hi, Well spotted.
Yes the center is steel.
It's the original idlers center with the bonded rubber removed.
I was gonna just bore the ally for the bearing but decided thet the steel would be less prone to wear during future bearing repacements.
Maybe a bit overkill but i don't like doing things twice.[/quote]

that is using your noggin for something besides a hatrack .

thanks for being so patient with answering my ????'s.

i really appreciate it.

leon

After reading this, I have no fabrication skills what so ever......

My god!

Cory

NakedFun wrote: After reading this, I have no fabrication skills what so ever......

My god!

Cory

oh yes u do.

Finally got the head fitted and as usual the top idler rubbers are well past their sell by date so i knocked up some billet substitutes similar to those available from APE etc.
I used the original hollow dowels from the old rubber blocks pressed in the center to lock the whole assembly together.



While i was at it with the hammers i threw together a manual tensioner from an ally offcut, some nuts and a stainless bolt with the head machined round.







Just need to degree in the cams and that's the bulk of the motor done.

Couldn't resist fitting the shiney backplate for the Electrex ignition.



And set about making a stone guard from a later model alt cover


The whole thing was reduced in height as much as possible


And the end welded back on


I built up the inside of the joint with weld so that the covers edges could be profiled for a rounder appearance to match the early motors covers and have begun cutting away the rest of the case so that ignitions shiney loveliness isn't fully hidden