Blown motor

Really Mr Wookie you are a legend. Thank you.

Hey so i feel like i should ask the question how do you rebuild a motor Well and solid. Like anyone got any secred sauce.Fuck it i am a virgin at this .....So any advice for a newbie.. Thanks....

Factory
Service 
Manual

You will also need some precision measuring tools and some accurate torque wrenches.

Also, access to a trustworthy machine shop that is familiar with these old engines, or your own machine shop and a pile of knowledge and skills.

If the primary drive (chain, clutch) is making a clacking noise at idle, the noise should disappear, as Wookie said, when you engage first gear and start to disengage the clutch. An original chain on a 45-year-old motorcycle will definitely make a clacking noise. You can find new ones on eBay for a few tens of euros (although 750 chains seem expensive). If, on the other hand, it clunks when you disengage the clutch and accelerate, then you might be worried about a connecting rod. A bal bearing will groan and make a rrrrrrrrrrrrrrrrrrrrr. rrrr rr 😄m 750 bottom end engines are very robust. There were many 750s in Germany: E, L1, L2, L3, and even ZX. There are many parts at reasonable prices on ebay.de or on kleinanzeigen. Good luck.

I have both the german  and english versions  trust me. I am on this. I live in both worlds. 

TexasKZ wrote:

Factory
Service 
Manual

+1 for the FSM - best advice I can give you is don't listen to that "bloke in the pub" who knows "everything about everything" !!

Use a genuine Kawasaki FSM vs others, if you can.

Don't let a few pennies make you wish that you had.

😉

  When splitting the case do you need to remove the oil pump and drive chain also. Also i have some shiny silver in the oil pan. If we are right the bearings are usually brass. We are going to check the timing chain next.

As you are new to this game I strongly suggest you follow the manual "step by step". You need to remove all the side covers etc and the shaft holding the starter clutch and primary drive. Is that "rubber debris" on the oil pick up ? did you find any worn/loose components yet ?

Yeah it was all soft material on the oil pick up. Nothing is showing signs of wear but we do have way more silver flakes than i would like to see in the oil pan.

Larry G wrote:

Yeah it was all soft material on the oil pick up. Nothing is showing signs of wear but we do have way more silver flakes than i would like to see in the oil pan.

Post a pick of the flakes if you can, if there is no play in the con rods where they join the crank and that debris is soft it may only be the clutch basket dampers and "cush drive" rubbers that are worn giving the knocking noise ??

 
The flakes are not magnetic.