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

Another basket case project, but with potentially a different end goal! 2 weeks 5 days ago #22158

  • StanG
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Hahaha, that's a funny story about the cleaning lady. As they say, loose lips sink ships! Definitely you need to keep your wife happy.

Thank you very much for the offer Paul! You know, mine is A4, so it would be good to have it on the shelf and for reference when I get back to building this current engine.
The 79 - 81 models are almost identical and many similarities to the 82 A4. When I said I 'pulled the plug' on that engine I meant I am not going to spend money now on pressing the cylinders, honing, anything requiring a machine shop, and major like those piston rings and cylinder head gasket. But I will slowly sort out what I have to get as far as I can with what I have.

If you could print the files and send me a copy that would be great. Just that parts book, I have all the manuals. Please send me a PM about this.
1982 Kawasaki KZ1300 A4
Building an engine from random parts. This will eventually morph into building a bike from random parts - if it ever happens. Need a frame to begin with.

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Another basket case project, but with potentially a different end goal! 1 week 2 days ago #22300

  • McBoney
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Quick update: old pistons have gone for machining to drill an extra 10 oil holes per piston. I'll post pics when they are done.

Other thing I have been doing is painting all engine cover bolts black... very tedious, but hopefully worth it in final aesthetic appeal. Here they all are drying on the radiator together with the two reed valve caps, kindly donated to me by Frank.



The one engine cover that I messed up with bad paint has been bead blasted. However, I can still see the slight imperfection which did show up in the paint last time round. The machinist says it is a fault in the casting and he reckons I should do a very light coat of filler so it won't show up again.

You can just see the slightly darker 'fissure' running vertical from the 2nd A upwards... ignore the horizontal scratch, that will polish out and/or be covered by the paint. As I have seen the casting problem come through the paint before I am slightly nervous...



....[sigh] its never straightforward is it?

Paul
Six-Pot-Cafe in the making...
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Another basket case project, but with potentially a different end goal! 3 days 17 hours ago #22352

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After three failed attempts... victory!!



Now the wait is on the pistons with an extra 10 holes each drilled into them, then assembly of the engine can start again.

Starting to think about the frame now, and in particular the forks. Öhlins are quite dear I have found out. There are other upside down forks that seem just as good and a fraction of the price. For instance; Ebay UK currently lists a GT650R USD complete front end for £325 (item number 283294314406). That is forks, triple trees, two brake discs and callipers, brake lines, mud spat and the wheel. .... just one second hand Öhlins fork costs that amount! No idea if it will fit, but just to show the price difference out there.

Paul
Six-Pot-Cafe in the making...
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Another basket case project, but with potentially a different end goal! 3 days 6 hours ago #22367

  • Bucko
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Looking pretty nice!
Hello from Canada's We(s)t coast.

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Another basket case project, but with potentially a different end goal! 3 days 6 hours ago #22369

  • StanG
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Before your guy will machine the pistons, I just quickly want to show exactly how they look in a close up. I think you mentioned a few posts ago that the bevels are different angles, so I'd like to clarify all the info, as things might be different from a ZN piston.

As I mentioned earlier, there is a machined groove. From my crude measurements with common calipers, it shows 0.55 mm. If you go 0.5 or 0.6 wouldn't make a difference I bet. After doing this to the desired depth, the beveled edge could be touched up slightly to what looks like 45 degrees angle.

There is also a minimal bevel on the top edge above the oil ring. It's not as pronounced as the bottom bevel. Can you see it? I haven't noticed it before, but it's there. Same thing the second ring - but seems to be a little smaller. They both look like 45 degrees. The top ring groove teems to be the same.

You can also get the cues about the measurements from the photo. I don't think it has to be super precise - there is no piston ring going in there.

Hope this helps!

Cheers, good luck!

1982 Kawasaki KZ1300 A4
Building an engine from random parts. This will eventually morph into building a bike from random parts - if it ever happens. Need a frame to begin with.
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