Low Compression = Pi**ed Off

[z1000puddin]

RINGS !!!!!

Leak down test showed --
Valves seating good no leaks BUT leaking bypassing the rings & out through the crancase breather (#1 & 2about 30psi) (#3 & 4 less at 15psi)

I will pull the barrels of & fit new rings first, I will be looking for a set of 1015 barrels now !!!

Thanks for the help gents

stu

P.S Chap at highland dynos sussed out my carbs so the 1974 28s are staying on the bike (Al / Roger)

[z1bman]

keep us posted on the outcome

[z1000puddin]

Well I whipped of the head & barrels/pistons
By luck my new wiesco rings arrived this morning

The old rings were quickly taken off and I placed them back into the barrels with the new rings just below.
You dont have to measure the difference-- You can actually see it !!
This is even with the old ring on the unworn part of the cylinder (about 12mm down)

New wiesco ring end gap 0.025"
Old ring over 15thou



There are a few very slight vertical scoring,but I am going to get it back together & run it till the end of September/October

I put the piston in the cylinder with out the rings and on all 4 cylinders I could just about get a 4 thou feeler guage between the piston & cylinder wall on the thrust side.
A 5 thou would not go in.
I have my eye on a set of 1015 barrels from the states.

I have the piston rings on & the pistons in the bores-- ready to fit and I cannot find my new base gasket !!!!

Anyone Got a spare base gasket ???Zpower are on holiday this monday and I need to get this thing back together for next weekend

Stu

[z1bman]

hi stu you have got some serious scoring in that cylinder to say you have only done 100 miles. have you had any blast cleaning on the engine? the photo's look like you have contaminated oil or the oil is breaking down due to getting too hot. have you got a oil cooler fitted.is there any scoring on the pistons. have you tried john browse for a z1000 cylinder i know he is expensive but i think he would be cheaper than purchasing one from the states. unless you have found the cause for the rings + cylinder wear putting it back together will be a waste of time + money

[z1000puddin]

z1bman.
Petrol Wash!!
Contaminated oil with petrol due to excessive over rich 28mm carbs (They have been on the bike for the last year).

The main jet went from a 122.5 to 120 by me.
When on the dyno the man went down to a 114 Dynojet and he rekons I should be down to a 112.
Could not get the carbs spot on due to the oil contaminating the the spark.So I decided to stop at the 114 mains.
I am not sure how you can or if cross ref. Mikuni to Dynojet
The bores have done a lot more than 100miles (This is what I have done since I put it back together)They have done around 1000-1500, but were deglazed 100 miles ago.

My fault for leaving this long to sort the carbs.!!

The picture does make the scoring look worse than it actually is.I can barley feel the scoring with my finger nail
Kerker oil cooler is fitted to the bike.

stu

[z1bman]

what exhaust + air filter system are you using. 112 main jets are about right if you are using stock air cleaner + exhaust system. have you checked the needle position post some photo's of the pistons if possible. a colour tune will give you a good indication if the engine is running with the correct mixture at different revs

[z1000puddin]

Harris pipe with race baffle.
K&N individual filters

We did not look at the needle positions as the bike was misfiring due to oil fouling the lugs.

The dyno graph showed that it was well over rich pic of the psitons

[z1bman]

hi stu you really need to find out what your carb settings are ie main jets pilot+ needle position. have the carb's been dyno jetted with air corrector jets.look into the two holes in the mouth of the carbs if the jets have a slot across the jet they have been modified

[Rich]

http://www.wiseco.com/PDFs/Manuals/RingEndGap.pdf

[z1000puddin]

Z1bman,
Once I get the girl back together and no oiling issues,I will have the bike back on the dyno to have the carb settings resolved.

Like I said, we would have been wasting our time trying to get the carbs done when the oil fouling issue was still present.

I will check out if this mod has been done, I must say I have not noticed.
**JUST CHECKED THE MOUTH OF THE CARBS & ONLY ONE SMALL HOLE CENTRE/BOTTOM & ONE LARGER HOLE ON THE SIDE WALL BOTH ARE ROUND.(I will post a pic later)

Rich, Thanks for the pdf, but these come with the new rings so I have about 8 of these

[Rich]

Don't forget to gap the rings before you put it together

[Big Fluff]

4 thou' piston to bore clearance is pretty much on/past the limit.
If you 'gun it' often, expect excessive crankcase pressure and watch for oil spilling from the breather (route hose away from rear tyre).

[z1000puddin]

Big Fluff,
Yeah I did figure that out,but I had already bought the rings,
So the bugger will have its BLOODY neck rung for the rest of this year.

I intend to pull it off the road end of October.

I will be looking at a set of 1015 barrels & 1075 pistons over the winter.

I have my eye on a couple of sets from USA.But I will check on Mr Browes to see what he has.

I do have the baffles removed from the crankcase breather & a stainless braided hose routed up undernmeath the seat,into a small "trap"


STU

[z1000puddin]

Just bought me a set of 1015 barrels
Just getting ready fr the winter rebuild- still not sure if I go 1015 or 1075 ??



Description as follows
Kawasaki KZ1000 A LTD Factory Original USED CLEAN RARE LOW MILEAGE standard bore engine cylinder assembly........Complete cylinder assembly that was removed from a running engine w/LOW miles.......Excellent clean cylinder w/no rust/corrosion and factory aluminum finish still looks and shines great and cylinder walls have no damage and look great........No damage/cracks/breaks and all fins are nice......Everything was working perfectly when removed 6-1-11.......PERFECT FOR YOUR RESTORATION NOW Comes complete as shown in pictures---BOLT-ON READY TO USE NOW!!!!

**REMOVED FROM A 1977 KZ1000A w/11,000 miles**
I have bought items from this guy before - all quality parts.
Total including shipping £109

[DogsbolloxofZ1B]

No4 liner is lose in its bore though... Need make sure it can't spin..