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Got to have a talk with my cylinder head specialist. He said all my intake shims would be between 255 and 265.

Well, I have one thats going to need a 270!!!!! WTF!!!!

oh man you gotta be getting excited!

leon

531blackbanshee wrote: oh man you gotta be getting excited!

leon

YOU BET!!!!!!! I just hope I can get the pistons back into the barrel without any hassle. Going back through my notes from when I put this motor together, I had 225~240 pounds of compression!!! I just hope I will be able to start it up again. I don't know if replacement hips can take kickback. This motor bit me a few times in the past!!! I don't need another knee in the jaw!!!

Time to get back to work.

Like Doug Wolfgang used to say, "We're digging". About went through a change of life getting my cylinder down on my pistons. I used Suzuki's ring compressors for the first time on a KZ motor. Boy do I miss my factory Kawasaki ring compressor tool!!!! A 10 minute job turned into a two hour ordeal!!!!!

This is also completely flat. ZERO warpage too!!!



Suzuki ring compressor tools.




Finally!!!

Cylinder head is on, and just waiting for all the TB-1211 to dry. I am done for the day. Like I said in another post, I use TB-1211 on my center o-ring. Its just extra insurance against an oil leak starting from the most common area for a KZ1000 to develop one. Unlike ATV silicone, once TB-1211 sets up its impervious to oil or gas. All the years I spent road racing, you just can't even chance the smallest oil leak. Just a mist of oil on your footpegs can be very hazardous to your health. Let alone covering your back tire. My favorite gasket coating is the original K&W Copper Coat. Screw that spray on Permatax copy.

Now install and check my specs on my cams, and the motor will be done. Just all the little stuff to bolt on like the oil cooler.

What I need to know if I F/Ued and put my Dyna 3 rotor on my advance unit 180 degrees off. I have the trigger spot to the left of the 1/4 TDC mark. Anybody out there know if I am right or wrong on its placement. I don't need that loud gunshot when you are 180 off!!! .

Here's a little trick for people who keep stripping out the 6mm cam cap bolts. I have used it for years when installing BIG lift camshafts. The stock cam cap bolt is 6X45mm. Well get yourself some 6X50mm or 6X55mm bolts. Start bringing your cam caps down with the longer bolts. That way you are not grabbing just a few threads. When you get your cam caps down to within a 1/8 inch of the head. Remove the longer bolts ONE at a time and install the normal 6X45mm bolts. This should stop 99% of the people from ever strippng the cam cap threads in their heads. I have never told many people about doing cam caps this way. So consider yourself one of the fortunate few!!!!!

That's an extremely intelligent solution Dr.G....another question I had was "Who makes the TB-1211 you speak of?" I have not found it in another post......also you are quite a mine of useful information and I really thank you for alll the gems that appear from time to time

Here are a couple sources for TB-1211. There may be less expensive sellers out there. Ed

www.amazon.com/Three-Bond-Engine-Silcone-Gasket/dp/B000GZR4QC

4into1.com/threebond-white-silicone-liquid-gasket-tb1211/

Damn that is a good idea on the cam cap bolts..... I was so worried about them I replaced em all with heli coils before I sent the head to Jay.

Got the motor running, but when I finally got it started, it sounded weak. Just did not sound healthy like it should. Well I been monkeying around with it for the past two days now. The jetting was miles rich. Plugs 2/3 did not match plugs 1/4. I went down on the jets, and it still didn't sound right. The spark on 2/3 looked weak compared to 1/4 when I layed the plugs on the top of the motor. Started checking all the wiring from the Dyna box, the Dyna rev limiter up to the coils. Everything looked good. Decided to switch leads to coils and spark plug wires, and see if that same coil still had a weak spark.. When I loosen the nut for the trigger wire on 2/3 coil, it had about 2 or 3 strands left from the wire to the eyelet!!!! Well hell. Fixed that, now I got a seriously healthy sounding motor!!!

I can't believe how much I am dropping the main jet size for the attitude change from Chicago. Its 5,500 feet above sea level here in Prescott, Az. I even had to drop the pilot jet size too!!! I am going to lean the needle jet out too. I think I have lost more fuel from taking the carbs off and on than what I have burnt so far!!!

Since it is Easter weekend, I am not going to fire the bike up until Monday. I like to keep peace with my neighbors. I forgot how loud this bike really is!!! Plus I am going rabbit hunting in the morning!!!

PROGRESS REPORT.

After chasing a few electrical gremlins, and trying to get the jetting pretty close, I now have a motor that runs damn near perfect!!!!! Its amazing how electrical parts just seem to break just sitting in a box for 32 years. Only took four major jetting changes to get it real close. I had to go back to the 65 slow jet in the end. But what really puzzled me is that I had to go to a smaller air correction jet to get the low end to clean up. Had to drop the main jet, but had to keep the richer slow jet. I ended up with a richer needle jet too!!! So far no sign of any oil leaks from anywhere on motor. Compression is between 220 to 235 in all four holes. Wish I had a roller starter, this thing is a real bitch to kickstart!!!!

I went for its first test ride today. Very happy on the way it runs now!!! Pulls real good from down low without any stumble, or hesitation. Going to take off the number plates and stick a headlight in it, and go for a longer test ride.

I neighbor said he would record my bike running tomorrow so all of you can hear what it sounds like!!!! So stay tuned all your boys and girls until tomorrow!!!!

I took some photos of my KZ's bare chassis when I had all the bodywork off for its first valve clearance check.

You can check out all the additional frame bracing and gussetting that were added to make a KZ1000 frame handle around corners.

Nothing but the bare essentials on this bike!!!