Z1100r my tale of woe

[swampy]

Right then ok peeps who is the best company to take the crank too, to see if they can refurbish it roger upperton des not do cranks any more so thats him crossed off the list.

[tlc]

Debben know a thing or two.

[ADRIAN H]

Debben know a thing or two.

+1 for Debben

[ADE]

S.E.P Kegworth did mine
Ade

[ColSZ1B]

Whats the difference between 900 & 1000cc engines,is 1000 just an overbored 900, using same cranks ??

[Al]

There are two different KZ1000 engines. The first is the Z1 type which was built between 1976 and 1980. The second is the 1000J, or "J model" as it is called, and was built from 1981 until present ( currently only available in police motorcycles). These engines are different, but some of the parts can be interchanged, and this has caused much confusion. We hope this makes everything clearer.
The first example is simply a big bore Z1 900. This engine came with a kick starter and electric starter. The cam chain tensioner hole in the cylinder block is a rectangle. The ccs cast on the cylinder is 1015. The later "J model" has no kick starter, and the cam chain tensioner hole in the cylinder block is round. The cc's cast on the cylinder is 998. This engine also became the GPZ1100 in 1981 and '82, and virtually everything between them is the same. (The '83-'84 GPZ1100 was changed). Cylinder blocks and lower engine cases are NOT interchangeable. You can not put a J model cylinder on an older style lower end, and vise versa.
Cylinder blocks.. Not interchangeable. If you have a J model block/GPZ1100 block you must use a J model or GPZ1100 cases.
Crankshafts... Early KZ1000 used a roller type cam chain and the crank has that style center sprocket. J model used Hy-vo style chain. J model cranks can be used in early lower end if the center crank pin is changed to one with a roller chain sprocket. The J model connecting rods are approx 1.2 mm shorter than early style rods.
Cylinder head.. J model head has larger valves and ports. This head can be used on earlier style cylinder and lower end by installing APE #CCIA cam chain sprocket adapter in head . How to tell which head you have.. Early style heads have four factory drilled and tapped 6mm holes in the center to bolt in cam chain idler gear. Z1 900 heads have 6 mm exhaust studs, KZ1000 8 mm. On the J model head, the four cam plugs at the ends of the camshaft areas are bolted in, on the early style head, they just push in and the valve cover holds them in. The J model / '81-'82 GPZ1100 cylinder head has a larger combustion chamber than the early style head. When these heads are used on the early style motor, a compression ratio drop of about 2 full points can be expected.
Pistons... All pistons have 17 mm pin holes, but the J model/ '81-'82 GPZ1100 pistons have the pin hole lower in the piston to make up for the short connecting rod. All J model and early '81-'82 GPZ1100 pistons are the same ( '83-'84 GPZ has 18 mm pins ) Therefore any '81-'82 GPZ piston can be fitted to a J model engine to make a big bore engine. Pistons for the J model / '81-'82 GPZ1100 can not be used in a motor that has an early style long connecting rods unless a spacer plate is used under the cylinder block to compensate. If early style KZ pistons are used in an engine that has the short J model / '81-'82 GPZ1100 connecting rods, a special short cylinder block has to be used.

[wilsonsjw11]

Swampy,
Chris Applebee engineering for all crankshaft work and only over in Essex.
Get it welded and balanced while it's there too.
01268 776642
Regards
Steve

[ColSZ1B]

To ZORDED. Thanks for the info mate.

[swampy]

[img][img]http://i1244.photobucket.com/albums/gg574/paulkemp2/Mobile%20Uploads/20160423_111118_zpsfygsi8bh.jpg[/img]



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Some of the damage and blasting media we got out of engine. If you look closely at the oil pan you can see some of the metal particles.

[swampy]

This is how the engine now looks.

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I have now ordered a rolling total so far of £1900 of parts including a wiseco big bore kit, APE guides, stem seals, valves springs slotted cam sprockets, and HD studs ( it already had APE nuts fitted with std studs!?). All the other parts are kawasaki where possible.

[ADE]

Will be painful to start but at least you know what is in the motor.Hope you have no more grief and don`t rush it.
Ade

[swampy]

the only reason I went the wiseco kit and ape goodies is availability of oem parts and/or cost with regard to the ape parts.

[tlc]

Swampy.
You`ll be glad you went for the Wiseco kit. My dyno man tells me 80ft/lb is up there with modern big bikes.

[swampy]

Today the time I had spare due to the rain I spent cleaning and measuring vales and spring preload ( well Dave Capper done the measure part). Turns out both were 'plum ducked'. Should have just thrown em in the bin and saved a couple of hours . oh well you live in hope don't you.

[swampy]

Ok the plan so far is get SEP to do the crank as they have some parts and to build the best crank they can with what parts we can get our hands on.

The Head os going to Cambridge services for boring, new guides and valve seat cutting on there serdi machine for the new valves. Just have the wait for the parts to arrive from the states and other suppliers.

Just starting to think about some cams that are a bit hotter than standard good idea or bad idea people.