Restoring 1979 KZ1300 A1

2021-08-17 UpDate
Noticed a bunch of corrupted posts, no pics or texts. Fixed today.


She has been stored inside, under a blankie, since 1994. Bought it new back in 79 and rode it all over. Burned oil from day one, almost a quart every 225 - 275 miles. Eventually parked it and rode newer iron. Now, the itch needs be scratched.

Entire report here

Some pix of the starting point -



Entire report here





Entire report here

After a bath -



Entire report here

Plug shot - rich and oily, not good.


Varnished tank.. <sigh>


Carb cleaning..



Entire report here

She runs!
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Well, it's a start. If anyone knows anything at all about this engines please post up here or on my secured website, https://candybuttorg.ipage.com/cba/node

I'm looking forward to the project but need info about how best to handle the aluminum corrosion, sourcing parts, etc.

TIA!

dcarver

Cool! Was the oil burning thing a thing with them or was yours somehow a lemon? I always liked the transformer looks of those. And I will add, I am SOOO GLAD I live in the desert where that motor would still look as if new under a coating of dust! Oh, and I am totally diggin the 70s rocker dude paint job! LEAVE IT LIKE THAT!!!! Too cool!

I remember back in the late '70's when Kawasaki launched this model. At the time I recall saying to myself "What in the hell would anyone want with a 1300cc six banger? I mean, really, just how BIG a MC engine do we need?"

Silly me.

Of course that was back in the days when 750cc was considered big and then Norton upped the ante with its 850 Commando.

Heck, I remember seeing a Suzuki Titan 500cc 2-smoke and thinking that's the kind of bike a guy could ride cross country. I was so innocent back then....

From what I've been able to research, the 79, 80, and 81 models came with incredibly hard rings. If not broken in 'hard' (motoman?) they would not seat and burn oil.

I'm very disappointed in the corrosion. I live in the central kali coast and we don't have salt. I failed miserably at prepping the exterior surfaces before storage. My bad.

Oh yeah, the rocker paint job remains! I even have a top case the same matched color!

When I bought the KZ, I had (and still have) two /2's. My /2 bud said something about 3 BMW's for all the pistons in that Japanese piece of shit!

Well, yesterday didn't go as planned...

EDIT - fixed the link

I had one new in 79 as well and it burned oil like a lamp. I remember one trip across the US: I had ridden non stop except for fuel from Denver to Detroit. I was going over the bridge to Windsor Ont and the oil light came on so I shut her down and coasted into customs. I ended up pushing the bike out of customs to the nearest gas station - not an easy feat - where I added almost 5 litres of oil. I had run it almost completely dry (not sure what I was thinking - live and learn - or not)! It survived another trip out west the following year but the year after that, I blew a main bearing ruining the crank and effectively trashing the engine. I pulled it all apart and tried to smooth out the gouges in the crank, installed new bearings but it was all to no avail! I managed to pick up a very low milage motor out of a demo that was crashed for cheap and swapped it in. I sold it a year or so later and always regretted getting rid of it (in spite of the oil burning).

Good luck
Bucko

Linky not work?
In '78 I bought a new Yamaha XS1100 and rode that thing for 50k miles all over the western states. Loved that bike, probably my favorite of all time. It was the first new bike I'd bought so I was determined to follow break-in to the letter. Drove that thing so gently for the first 1000 miles and guess what, it always used oil, about 1 qt/500 miles. In hind-sight it needed to be broken in like motoman suggests... oh well, water under the bridge.

What happened yesterday? :eek1

My understanding is that in '81 Kawasaki changed ring metallurgy - and also that big K is known to have ring issues across several different models. Adding 6 liters of oil is HUGE, LOL.

My bud was working in a Yammie dealer and tried really hard to sell me an XS1100 but i HAD to have the 6. Honestly, this KZ has been a PITA from day one - oil consumption, low electrical output, failed regulators, etc. One trip I ran total loss ignition due to fried regulators and over charged battery. 5,000 miles of charging a new battery with a Schauer charger wasn't fun then but I grin at it now..

Thanks for letting me know the link was bad - here's a good one.. Candy Butt Association KZ1300 Project.

Yes, it was my understanding that they changed something, either the rings or the pistons to help control oil usage. Yes, sorry, that was supposed to be 5 litres

and today USPS delivered a new manual CCT - the stock ones are notoriously bad..


After reading some horror stories over on kz1300.com, I'll not start her up again until the new CCT is installed.

Making progress!

Apologies in advance for the lousy formatting. I maintain my own Candy Butt Association site, built on Drupal. For full high res pix and story, please click here, sorry for the extra work on your part. [/URL]

For reasons completely foreign to me, it's not possible to simply cut and paste from my site to other sites or from one site to another. Since I belong to more than one site, building each up 'pristine' is just too much work.

I did find a kinda-sorta work-around for AdvRider, my favoritest site of all - so it will give an idea of where the project is going, at least for all 5 peeps that seem interested, !

So here goes - and remember,
For full high res pix and story, please click here Candy Butt Association.

Code:

<p>Spent most of yesterday working on the mighty KZ. Initial plans were to:</p><ol><li>Check valve clearances</li><li>See what she looked like without the barn door fairing (still contemplating cafe KZ!)</li><li>Determine cam chain sloppiness and idler gear wear.</li></ol><p>I've already replaced the stock wimpy coils with real sparkies, did that years ago. The bottom coil has to be removed for valve cover</p><p>clearance.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/1.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/1.jpg"></a></p><p>These radiator shrouds were the 'hot' ticket item back in 1979 - they keep some of the engine<br>heat off the tank and rider.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/2.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/2.jpg"></a></p><p>Shrouds removed.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/3.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/3.jpg"></a></p><p><br>Yes, really. It takes all these bolts to keep the valve cover in place...<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/4.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/4.jpg"></a></p><p>Pleasantly surprised to see the cams and interior of engine were looking clean, clean, clean!<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/5.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/5.jpg"></a></p><p>Cam lobes - no pitting or galling, whew!<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/6.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/6.jpg"></a></p><p>&nbsp;<a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/7.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/7.jpg"></a></p><p>For manual crank rotation, removed the left hand side alternator cover. In a previous post, I had removed the RHS.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/8.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/8.jpg"></a></p><p>Could this be the source of my 1,500 crank buzzing? Look closely.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/9.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/9.jpg"></a></p><p>Ouch! What the heck?<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/10.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/10.jpg"></a></p><p>The problem - the pix doesn't' show it well, but the bolt ends are extending to far out and contacting the stator.<br>&nbsp; <a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/11.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/11.jpg"></a></p><p>Man, am I glad I looked at this - it's the cam chain idler gear and it's about toast. Non longer available from Kawi, either.<br>I think they are available from aftermarket though..<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/12.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/12.jpg"></a></p><p>Insert video here</p><p>Top of piston looks OK too..<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/13.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/13.jpg"></a></p><p>Numbers for documentation.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/14.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/14.jpg"></a></p><p>Engine numbers.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/15.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/15.jpg"></a></p><p>Valve clearance info. Most of the intakes are right at the tight side of clearance.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/16.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/16.jpg"></a></p><p>Part of the AIR induction system. Look at how rich it looks. Pure carbon..<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/17.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/17.jpg"></a></p><p>Reeds removed.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/18.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/18.jpg"></a></p><p>I had to to do it. Broke out the buffing wheel just to see if the aluminum would polish out. It kinda sorta did, good enough for now.<br><a class="colorbox" href="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/19.jpg"><img alt="" src="http://candybutt.org/pix/motobikes/resto/kz1300/2012-01-08%20Noise%20Found/19.jpg"></a></p><p>Many, many thanks to David E over at KZ1300.com - the Bible for all things KZ1300.</p><p>&nbsp;</p>

I give up.

No longer will customize posts for here,
it's evident no one is restoring a kz1300 but me!

So, the best I can do is a link..

If some other fine gentleman/lady is restoring a KZ1300 and wants to contact me, please do!
dcarver220b at yahoo dot com
clicky

Here is the latest update..

This is good stuff, many of us follow build threads but don't often post so keep us informed!!!!

Making progress!

2012-01-01 Rods off Crank

Permalink Submitted by dcarver on Sun, 01/06/2013 - 09:45.

Ray called, good news, all looking good down under.​

Shift drum and cam.
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Again.
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Carefully documenting where all the little pieces go...
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Shift forks.
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Main and lay shaft transmission gears.
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Transmission final output gear.
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Final output assembly.
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No clue.
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Ditto again on the no clue.
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Thrust washers and what not.
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Part needing replacing.. Ray - ignition timing chain tensioner?
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Let the games begin...
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Crank halves.
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Journals nice and clean.
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Modern art, KZ1300 style.​

To steal from Peter, Paul and Mary, "Where do all the pieces go?"​

She's a thing of beauty..



Complete resto project with text and pics here
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a buddy called me up one day & said come get this kz1300 if you want it 'cuase I'm hauling it off to the dump. ok.... why not. it had suffered a blown head gasket, that was replaced along with the chain tensioner but afterwards it ran ragged and rough. then it sat outside for about 6-7 years until he got tired of looking at it. I got it running but it sounded terrible. over the winter I tore it down a bit & inspected it. then I had my son turn the engine while I watched the crank & chains... hey... the cam chain went slack. well he had turned it backwards. the aftermarket tensioner was no good. coupled with miss firing coils and bad carbs... every pulse caused the chains to go slack and re-catch

anyway, good... you got the manual chain tensioner... that is the real killer.

dump the original coils they are junk. I used 3 ohm Accel coils (also lose the balast resister... no need)

pull the little plugs that cover the idle mix screws (pilot)... the carbs are lean and need adjusting. also, you can't properly clean the carb with the needles in place

best source:
http://www.kz1300.com/linkspage.html

after a tidy up & paint:



found some bags:

here....

http://www.kzrider.com/archive/viewthread.php?tid=24842

http://www.motorcyclistonline.com/features/v12_custom_kawasaki_2300cc/


there was a better site a few years ago (by the builder?) but I can't find it

I'm restoring a 79 KZ 1300 now.I am thinking about how to get the engine out without hurting myself,mabe a couple of friends will come over and help for a few cold beers.

Your project turned out great! WooHoo for you!

Ray is tearing her down!

Ray built this coolio engine stand.


I wonder what we'll find inside...


Slight corrosion on aluminum.


Messed up paint on valve cover.


Guess this is what happens when you don't properly store an engine...




Years of leaky carbs have made a mess.




One of many chains in this engine...


This nylon gear is notorious for failing... I think I have a new one already.


Ignition pickup coils.


Looks like a slight water leak down here...


Two tensioners in KZ1300 engine. Cam and timing chain.




Water pump impeller.


Getting close to getting some head. :)


Interior engine color looks good.. Then again, with the amount of oil that's gone through this motor, it *should* look clean...

I like the way Ray bags n' tags all the parts.


No need for new cams. These look good and spec out OK.


Oh my... no wonder theose sparking plugs were getting oil fouled..






The bores look ok, although Ray mentioned they are lipped at the top. The new pistons are 1 over, so this block gets the boring bar anyway.


This engine has NEVER been apart.. Ray has himself a virgin!


A pretty cool casting. Can't wait to see it all fixed up.




Lots of oil fouling.

I diggit. Love seeing motors apart and then back together