My KZ1300 project thread (photo heavy)

I've been getting the frame situated. This is a huge pain in the butt to do alone, but thanks to the suggestion of another member, it is at least do-able.





Slight problem, though. I bought a ZZR1100 cam chain tensioner to replace the stock unit.



The ZZR unit's on top, the stock unit's on bottom.
They don't match.

Suggestions?

the tensioner in the bottom photo is the ignition (and maybe water pump) chain - not the cam chain tensioner.

Nice job Brandon, worth hitting center and side stand next. Looking forward to seeing this on a rolling Chasis

Okay! Swapped the tensioners and I'm square now, except I don't have a gasket for the lower CCT. I'll need to either print or order one. That's on the list. I have no idea why I don't have a gasket in the gasket kit I bought, unless it doesn't require one (but that seems odd).

I installed the oil pan and righted the bike using my overhead pick points and a hand hoist:



However, I realized once I started poking around with the camshafts that the sump was going to be in the way as I wanted to verify the cam chain engagement on the secondary gear. Thus, the pan came off again. Just as well, as I butter-fingered a pick down into the galley and had to retrieve that anyway.

Hard to see, but here's the TDC mark for 1 & 6:



Here's where I ran into another bit of stupid.

You'll notice I have two camshafts here, as I should. When I removed them a year and change ago, I marked them for ease of installation: I for Intake, X for Exhaust.



Eagle-eyed viewers will note that the camshaft marked "X" is the one WITHOUT the tachometer worm gear.
I don't know how I did it, but I fucked up the labels when I marked 'em. Oops. That cost me quite a bit of cursing as I couldn't get the cam timing to work right!

Anyway, cams are now installed and timed!





My next task will be to check and adjust valve tolerances. From there I suppose I'll set the ignition timing and work on cleaning and reattaching the cooling system.

Following that I'll work on building the ignition system. I've not yet decided whether or not to use the Honda coils I have, or a Buick brick (I have both in my shop). Either way, I'm jettisoning the factory coils and wires.

[quote="brandonsmash" post=9146



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Something looks wrong in that last picture, the chain is not seated on the drive gear for the exhaust cam, maybe that's not a final picture or something. If you can still see light between the chain and gear something is not right.

In that last photo I've neither installed the cam chain tensioner nor bumped the crankshaft to set the chain in the gears. As it stands there are 17 links between the timing circles on the exhaust and intake cams, so everything just needs to be tensioned. Good eye, though.