KZ1000 Mk2 project

[eastlondon]

Aston,
Have you got any pictures and info. of your Z1 in the "before" and "rebuild" stage?

[aston]

eastlondon,
Not much pics of "before" project sit in my computer. My previous owner did project pretty much and Z1 modification was completed about 4 years ago.

I do MK2 project from scratch, so there should be a plenty of pics I will be able to upload.

I just got electric harness, AP brake caliper supports, KZ1000 J clutch assy conversion push rod, AS Uotani ignition, and etc last week.

[steve bowdler]

Aston where did you get the AP caliper mounts from ??

[aston]

My Mk2 will have AP2696 calipers. (same as my Z1) AP2696 is commonly used for Z modifications, thus there are number of caliper supports suppliers in Japan. PMC sells AP2696 caliper supports as regular inventory.
(Mine are "sort of" one off supports which are made of duralumin.)

[aston]

Hi everyone.
Another week to go before I get back in the UK.
I have got most of parts now. The last parts which I need to buy are engine parts. (top idler , HD chain, floating idlers, and etc.) I will get them this week and my shopping in Japan will be completed afterward. (no more spending money )

Tank blasted.
Small hole on tank, but should be fine to fix.





CR31 Carbs
This carb was fitted into my Z1 from brand new up to only 4,000km. I will retry CR31 carbs for my MK2. See how it breathes. If I do not like it, I will put it on ebay FS or whatever.









Brake caliper (NOS)
Nissin


Crank Bearings
Sets for MK2 (top) and Z1 (bottom)





Exhaust
Yoshimura style hand made straight 4-1 exhaust.
Ex manifold size is 42.7mm.

[aston]

Back in the UK last night and went to check my MK2 engine. (Frame and others are all in painting job right now.)

A positive surprise. Bike was dirty at the beginning and did not even run when I bought it. But this MK2 may be a jackpot.

Clutch Assy (Left Original, Right KZ1000J/P which I will fit in)




When I saw the original clutch basket, i was very surprised coz basket was super clean. I have not seen such a good basket for long time. (Although I will try to fit KZ1000P clutch assy first)


Oil Pump
GPZ1100F pump which I will fit in. (Because of oil cooler, I need a bigger capacity pump)




Crank shaft.
In short,this crank is super condition. I will do disassembling, cleaning, balancing and other works next week. Hope I can post pics of crank jobs.
I am not really sure if I need to replace crank bearings at all.




Crank case is now stripped and waiting for blasting and painting job.


Original Pistons
KL250 sign engraved on the piston surface.




Cylinder Head
Painting was worn and head was dirty first at glance, but inside of head is super. No cracks, no loosen threads, or etc.











Transmission assy.
Almost NOS. Really nice. No sign of usage at all. Is this really a 30 years old transmission?????








Other pics of engine. I will post more pics when engine work progresses.

[Al]

aston, whats the story with the inlet cam caps?
They look new or have they been cleaned independently?

AL

[aston]

IN cam caps should have been cleaned independently prior to my picture taking. (EX caps might have been with oil.)
I will check them again next week.

Both EX and IN cam caps are original amd every cam cap threads was fine and no helicoils are needed. (good news for me.)

[aston]

I went to the garage and done the crankshaft disassembling today.
BTW, head picture first.

Cam caps have not been polished. I got talked to a mechanic and being informed that almost certainly EX side cam caps have red-blown colors due to the heat effect, but IN side caps stay sliver color. I checked my spare MK2 head and found exactly same.






Crank shaft disassemble.

I was very impressed 2 things.
1: condition of crank
2: skills the garage has.
Even in Japan, not many garage can do Zed crank recond easily...







Pin is fine cond.


Close up pin and web.






This is a close up pic of one of crank web. Oil sediment is found in this crank web. My crank is not having much sediment. However, without disassembling the crank, I could not see how dirty the crank was...


Crank races. Inside races did not have any sign of worn or burning surface. Very healthy cond.


Conrods, bearings, races, and pins are all fine.


Half way through.


I will do some horning inside crank races.


Kawasaki SS750 Crank in service
One of conrod is bent and waiting for recond.


Conrod bearings are all fine.








These washers are in good cond,too. Kawasaki never
provide those washers as spare parts. I am lucky that I do not have to find crank washers. Where can I find them if I have to search for?


Once again, no sign of burning of crank pin. I saw very bad cond of Zed crank in Japan last month. If crank pin is given excessive pressure or heat, eventually the metal surface of pin is peeled off and crank pin/web are no longer usable.






checking the tolerance of crank.






After polishing, balancing, horning, and assembling, crank will be checked and adjusted before welding pins. This is a Suzuki GS1000 crank as a example.




I will take some more pictures next week.

Cheers,

[ted1r]

Wow Aston this is going to be great when it is done,look forward to Stafford show.

Regards Ted

[aston]

Ted,
yes, see you again at Stafford show.
Im sure MK2 project will be completed by mid Sept.
Hope it will turn around bit earlier... I want to enjoy riding under the sun

[stephen parr]

Excellent pictures Aston, and very informative.
See you at Stafford with it.

[aston]

Stephen, see you in Oct. I believe the project will be completed by that time.
(But I will miss the best season of UK.....)

Some more progress of the project

Crank case is in glass blasting.




This is 1980 KZ1000 MK2 engine VIN Number.
I just bought complete 1979 KZ1000 MK2 (A3) engine short while ago.
That engine has Vin number of KZT00AE 077xxx




Valve guides are all fine cond.




Crank Shaft is in cleaning.


Frame is powder coated now.


BEFORE










AFTER








Front folk tubes are also powder coated.



I will post more pics once I come back from Spain.

Cheers,

[aston]

Sorry to be lazy, but my MK2 needs few more weeks to complete.

Crank assembling.
























Building up the bike



Crank case is my spare Z1B engine to check alignment.






Head and main case work
















Sept 17th














06th Oct 2009




























Hopefully, new engine can fire this week - next week.

Cheers,

[phil churchett]

Looking good Aston, but come on, stop messing about..... get it finished
[and remember to tell the others on here what bike you recently bought].