Another basket case project, but with potentially a different end goal!

Hi all,

I took the plunge and two months ago bought a basket case 1979 KZ1300 A1. It was all I could afford and attached a pic of the bike as bought. I have always wanted a six-pot after starting out as a student with a Z400 B1 and then (still!) a 1982 KZ1000P.

I am reasonably mechanically minded, but this is first time I'm taking on something this big and complicated. I have the workshop manual and a parts manual and am approaching the project as a large meccano kit. Doing it bit-by-bit. There is no deadline, it is going to take as long as it takes.

Situation now is that I have taken the bike and engine apart completely as everything was rusted stuck. After a month soaking in diesel the pistons were still stuck, so I had to resort to a mallet, a block of wood and a good hour of 'gentle persuasion'. The liners had already been over bored and were so rusted there wasn't anything left to do with the block other than use as a boat anchor, so I needed a new cylinder jug and pistons. I found a good second hand one in the US (I am based in London) and I got that reground. Top end just needed cleaning, valve lapping and head skimming.

In the meantime I'm starting to think about paint scheme for the engine. Sliver aluminium block with anthracite grey covers and black bolts is the current theme, but finding heat resistant paint other than silver and black, and a large enough oven to bake the parts in is difficult!

Now for the potentially controversial bit: [..... shape intake of breath.....] I don't think I will be returning it to stock. I want something special, so am thinking to go the brat/cafe racer way.

Ok, now that probably half the forum audience has clicked away in disgust, here is my explanation/justification... (other than: Its mine, I can do what I want! )

I attach a pic of my KZ1000P that I have taken as far as I can without being able to return it to the full-dresser police bike I bought. I purposely did not take it further as I want to keep the option to return it to a stock CHIPS bike as the parts are all original and I have its history. I quite like this style and I think I may be the first to attempt this with a KZ1300 as I have not found any pictures on the internet/pinterest etc. showing a KZ1300 styled as a true cafe racer (...and there may be a reason for that! I guess I'll find out).

As the KZ1300 is a basket case with very few useable original parts and no paperwork etc, I feel less guilty to take it away from stock and build something different. I have no idea exactly what it will turn out like and am currently concentrating on getting the engine back together and in the frame. Then I'll start tinkering with the style. It might turn out a little like the El Diablo rocket-garage.blogspot.com/2016/06/kawas...300cc-el-diablo.html (and that would be a great result!) but maybe not... I like the KZ1000P rounded, sloping tank better than the KZ1300 and I like the large round headlight as seen on the Red Rooster www.motor1.com/news/93503/krakenhead-cus...ter-kawasaki-kz1000/ ... we'll see where I end up.

For now I just need some pointers with regards to putting the engine back together and in the frame for a mock-up (see other threads), and if I can't find the answers in the various (extensive!) threads posted here, I'll ask via the forum. I tend to be able to work on the bike only every now and then so updates may be far and few between... but I promise to post stuff as it happens.

In the meantime thank you for your welcome (some members have already been in touch) and for the helping hand and suggestions that hopefully you all will lend.

Cheers
Paul

Lots of potential. Looking forward to seeing you realize your goals.

Good Luck!!

hi from NZ
i would imagine most if not all the other members on the site are pretty respectful of each other, and though your bike will obviously not end up in a original form, i think you will find plenty of interest in your project.after all im sure we are all here out of our common interest in al things 1300 zed or Kzed
trying to restore a 1300 to original form these days (especially if a lot of the bike is either missing or severely damaged) is a pretty Tall order due to the unavailability of many parts or just the sheer price alone can be crippling.
in my mind their will always be a place for altered bikes as their is for the completely original ones.
Aside of the obvious experience a site like this can divulge upon the needy i joined the site for the minds of people around the world who wish to come together and share their various motorcycling experiences, if you get a chance to read some of the stories in Daily chatter you will find this to be the case of many others.
Im fortunate to have recently acquired a 1984 Z1300 from Australia that is 90 percent original, so with some MONEY and patience ill get that to original factory spec.
however my first one a KZ1300 ex USA was a dogs breakfast, so have myself gone down the road of building something Kawasaki would not have anticipated im sure.
best of luck to you mate, hope all goes well
Dion
pic is rear of the KZ1300
have fitted Yammy XJ550 seat and tail piece that i have modified to take Ducati 996 tail lenses
i got the idea from Rob another 1300 member
subtle but visually for me make the bike look smaller yeah that's the ducks disease issue taking over!! HA

Hi McBoney

Welcome to this site. Since you are based in London there are quite a lot of people from this Island ehe in the forum.

And yes, it is yours and you can do whatever you want with it. Just as long as you provide us with the pictures we are fine with it. If you are aiming for something similar to your police - that will be interesting to see.

Wish you all the best
Holger

Hi all,

I took the plunge and two months ago bought a basket case 1979 KZ1300 A1. Pic as bought hereunder.

Situation now is that I have taken the bike and engine apart completely as everything was rusted stuck. After a month soaking in diesel the pistons were still stuck, so I had to resort to a mallet, a block of wood and a good hour of 'gentle persuasion'. The liners had already been over bored and were so rusted there wasn't anything left to do with the block other than use as a boat anchor, so I needed a new cylinder jug and pistons. I found a good second hand one in the US (I am based in London) and I got that reground. Top end just needed cleaning, valve lapping and head skimming.

In the meantime I'm starting to think about paint scheme for the engine. Sliver aluminium block with anthracite grey covers and black bolts is the current theme, but finding heat resistant paint other than silver and black, and a large enough oven to bake the parts in is difficult!

........

Update for today is that I have cleaned the jug with a few basic tools and am half way through masking it for paint (how does one get clean masking edges with curved sections?? I tried knifing the overhang with a Stanley knife, but still not a very clean cut).

I have also spray painted one cover as a test with Motip heat resistant paint, colour Dark Anthracite. I chose this as it can go directly on (sanded) aluminium and for curing can go into the oven for 60 mins at 160C. Having done that the paint still felt a bit soft, but more disappointingly, it was matt. So I covered it with some Simoniz clear lacquer (although not sure if that is heat resistant) to get some gloss. Hereunder a pic of the result. Looks OK - apart from the blemish in the middle where eager-fingers-here tried to feel if the paint was still wet (it was!)

...grr... some polishing to do.

Anyone have any ideas where I might get heat resistant paint colours other than black and silver? Most heat resistant paints are not suitable for aluminium....

I have heard Hammerite is heat resistant, and for water-cooled engines that don't get so hot that could work... they have a very nice dark grey and I know that finishes gloss and rock hard, which for the covers where the boots rub, it will need to be.

Paul

Hi McBoney, just a word of caution from past experience. The Alt cover in the picture be very careful that you don't overtighten either of the two lower bolts at the bottom of the cover as there is no support directly behind the cover there you can easily crack the cover behind the bolt hole and end up with a oil leak. And you may think its the gasket by mistake.

Just my 2 cents worth