My KZ1300-A4

Hey all.

First off, just wanted to say a big THANK YOU for creating the site. It has been invaluable as I delve into my own KZ project.

So - this is my bike

When I bought it last year, it had a coolant leak from one corner of the cylinder head. The previous owner had bent a valve during a valve shim check and adjust. He had removed the head and fixed that, and then replaced the head with an aftermarket gasket, and hadn't managed to get it to seal. He had then purchased an OEM gasket, but never got around to doing the head rebuild. Consequently I got the bike for a fair price (500 bucks).

It is actually in pretty solid shape. Only 32,000 miles. Previous owner already replaced the cam chain tensioner with a ZX1100 version, so that is done.

So now, it falls to me to rebuild the top end and get it going. Here are a few piccies of progress.

Cylinder head off:

I decided that since I had got this far, I would pull the water pump impeller and inspect the seal.

I'm glad I did, because it was obvious that the mechanical seal has failed. I also discovered that the owner prior to the previous owner had removed the cylinders for some reason, and there was a LOT of silicone sealant everywhere. I agonised about it for a while, but decided that I was concerned about blocked oilways (the previous previous owner had silicone sealant all over a bunch of O rings), so I removed the cylinders also.

In doing so I broke the plastic bevel gear (I'm pretty sure I broke it, I don't think it was broken when I got it)

Anyway, that brings me to today.

With the help of Strate6 I just found a used cylinder block on ebay which has a bevel gear in it, and should do the job, so pretty soon I will be doing some clean up, and starting on reassembly.

I think since I have the head off I will go ahead and replace all the valve stem seals (I have those from the remainder of the gasket set that came with the bike), and hopefully I will get this beastie up and running.

I plan to ditch the vetter fairing and boxes, although may need the fairing short term while I find a suitable set of headlight ears and headlight.

That's my story, and I'm sticking to it. :lol:

Wish you all the best in finishing this project and being able to enjoy hwo it runs ...

Holger

What are the cylinder bores look like - I mean if you have got this far......

The cylinder bores looked pretty good to me. There wasn't anything that jumped out and said "rebore these now", although you make a good point.

While it's apart, it would be good to:

* Run a taper gage through the bores.
* Take a straight edge over the gasket mating surfaces.
* Re-Ring the pistons after they pass inspection.
* Plasti-gage the bearing clearances. (Silicone could have found its way to those oil galleys
*Assume that the valves need a lap or grind, with new valve stem seals.
* The factory shop manual will provide you with all of the needed inspections for both the block and head.
* Pay close attention to the water pump shaft, they have a tendency to corrode.

Thanks for the photos and pictures, it looks like a great project.

All good mate, very interesting.

If you are buying new valve stem oil seals, try to get the BLUE teflon type.

They are much harder than the K ones & last much longer.

Normally cheaper too...........on EBAY.

Pete F