Iam restoring one also got the frame back from powder coating this week and soda blasted the engine today.I did'nt tear it down as it had 150 to 160 lbs comp.across every cyl.Like to see the tear down and rebuild of the engine on yours.
YES.. but work has me swamped. The head was installed, the head gasket leaked... typical of cheap head gaskets. Get your gaskets from the feller in Germany. When head was removed, 1 scratch found in bore.... So off to LA Sleeve for new pressed in liner, bore.. it all takes time..
This, my friends, is true sex-cylinder porn... This KZ has two alternators.. one each stator on each end of crankshaft. It was available from Kawi for a limited time, I scooped one up in 1980 and another just a couple of months ago from a dis-mantler by the name of Dave Morgan and PsychoCycle. Great guy. It's interesting to note that this stator cover has none of the honey glow covering of engine oil as does the rest of the engine internals. IIRC, the RHS was the orginal stator installation. The LHS was the rare and optional stator. Crankcase cover, left-hand side. This is the optional stator assembly from the factory and required a new cover and what not. This side, the optional stator side, has troubles. See the wear marks on the rivets? IIRC, these marks contacted the junction point connecting all 3 phases to the RR. On the stator, the wear point is shiny and obvious. Starter motor drive gear mechanism. One very worn (timing) gear? Check out the hooked teeth in that baby. I'm hoping somebody is making a gear out of better material than OEM these days.. Screw the Kawi, anyone else spot the nice Transalp in the background? I have now clue what this is... . Count 'em' baby. 1 - 2 - 3 - 4 - 5 - 6... Ooooh! I am not smart enough to know where the 1 quart every 200+ miles was going.. but looking at piston 2 from left... Frankly, I'm suprised at the <lack> of oil carbon buildup on the piston tops. This bike was an oil-eater from day one. Ray - what is the view here.. bottom to top? and what's at the top? Gouging at TDC? My favorite pix of this entire sequence. The DEVIL needs be unleashed from gates of hell! I love the patina of these internals parts. Castrol 20w50, for better or worse, was this engines diet. Of course, I had to run that heavy viscosity due to oil consumption. Looking at the rotor magnet cracks, I wonder if they need be replaced or will they grenade later, taking a newly refreshed engine with it? When all else fails, get a bigger air impact wrench... How cool is this?! For me, this is way cool! I've wanted to have this enigne run right since I was making payments on it back in 79. Looks like Ray is getting parts ready for shipment to the machine shop... Yep, and now the secret is out! Off the clutch side of things... Uueww, gucky. I never 'hot-rodded' the kz, as too techs told me it was a 'fragile' engine as compared to the kz1000 or Suzooks that were dominating the drag strips at the time. This is not the clutch though.. I think it's a harmonic dampner. Ray? Help me out bud.. HOLY CRAP, Batman, I'm glad Ray is working this, not me! Got to love Ray's attention to detail... The clutch on the Kz never gave any trouble at all. Then again, I was sedate. I have no clue, clutch inner-hub? A Dampening mechanism to reduce drive line shock? I'll say one thing, if Ray can ever get this engine back together, I'm fullly impressed.... Ray responds with what the parts are... Permalink Submitted by dcarver on Tue, 12/11/2012 - 15:08. I have now clue what this is... . That is the timing chain drive from the crankshaft. It drives a seperate shaft in the block for the ignition timing and a goofy plastic bevel drive for the water pump. When I get the cases split you will see at least two or three more chains in the bottom end. The othe strange looking device is the oil pump also chain driven from inside.
Never had one...can't say I want one..but it sure is fun looking at all those complicated engine internal parts. Thanks for sharing the details. More moxie here than I'll ever have. roy
Back in the day I went to the service school for that model. The first year problems were the lack of electrical power. People wanted to full dress them with all the lights,bells, and whistles and they simply ran out of juice. We didn't sell many of them as we were also a Honda dealer and the Goldwing was the premier touring bike at the time. The crankcase according to the Kawasaki reps was the largest single casting that any motorcycle company had done to date. You are fortunate to find that alternator mod. I don't know if you can fit any Hidenau's on it. Might be a little heavy for offroading.
2012-12-13 More Disassembly Permalink Submitted by dcarver on Thu, 12/13/2012 - 18:53. All Righty Then Ray has moved the KZ1300 to the 'indoor' and heated section of his spacious shop. After talking with Ray today, I think, in some kind of masochistic way, he's enjoying this project! Ray mentioned this is the rev 3 of the engine stand. Ray asked me my thoughts regarding replacing various gaskets, seals, bearings and what not. Instantly I recalled a previous engine rebuild I did, where, due to lack of finances, I had to use used seals and what not - and I ended up rebuilding that engine twice. Oil pump. From the pix, wear looks minimal. Ray, correct me if I'm wrong, but the big hole at left - is for ignition coils, pick up plate and what not? Oil pan.. not too bad considering the miles... One issue with the 79 A1 and 80A2's was oil depravation due to the shallow pan. Many replaced the pan with a later model's pan that was deeper. If I can find one, I will too. The only real Uckkk found in this engine.. bottom of the pan. Gearbox, shift dogs, shift drum all look ok. Another shot of the pan gook. Actually, thinking that this engine sat for over 8 years... and has over 100k on it.. Not too bad. The oil pan screen has some fibrous gook on it. Not sure what it might be.. But with all the fibrous/plastic gears, perhaps something from there? Parts baggies are us... Ray, what's that metal spiral winding of steel pix bottom? Shift forks look good.. the tranny was shifitng fine up to point of not being ridden. Never hot-rodded, or shifted w/o clutch. Main bearings look good too. Ray reports back that lower end rod bolts are 9 bucks each.. Do I want to spend $$ and look to see how rod bearings look? Fuck Yes! We are waay too deep not to look at everything to be sure all is well... Whoever desinged this engine must have been on crack. I mean really.. too many chains, too many plastic gears, too much of too much. No wonder I love it! I like this pix.. A certain beauty in the elegance of a spiral cut gear spinning next to a crude-ass hyvo chain... .008" of crankshaft lateral play. Interesting,as this engine had a horrible growl at 1,800 rpm when I got running a year ago, about 10 years after it last ran. The stator on the LHS has wear marks from the rotor hitting the 3-phase coils to output wire connection.. and I really thought the crank was the issue. Now I'm not sure what we have here... Last pix - man, there are alot of parts laying around... edit reply
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. Again. Carefully documenting where all the little pieces go... Shift forks. Main and lay shaft transmission gears. Transmission final output gear. Final output assembly. No clue. Ditto again on the no clue. Thrust washers and what not. Part needing replacing.. Ray - ignition timing chain tensioner? Let the games begin... Crank halves. Journals nice and clean. Modern art, KZ1300 style. To steal from Peter, Paul and Mary, "Where do all the pieces go?" She's a thing of beauty.. edit reply
2013-01-21 Taped for Powder Coat Permalink Submitted by dcarver on Wed, 01/23/2013 - 03:57. Ray's been busy and has everything taped for powder coat. It's a special high heat tape, Ray said it's a pain in the ass to work with. Me thinks this is going to turn out most excellent!
2013-02-02 Cylinder Issue Permalink Submitted by dcarver on Sat, 02/02/2013 - 22:24. The first apparent problem with this rebuild - a bit of weakness in the cylinder head around a water jacket. Ray thinks it was exacerbated by the sandblasting process. reply
2013-02-08 Engine Teaser Permalink Submitted by dcarver on Mon, 02/11/2013 - 08:05. Powder coating is back, and it looks AWESOME! Check this out - truly fooking amazing. Most impressed. It was Ray's idea to black out the cylinders. I'm thinking it will lood really good once the engine is in the frame - to have a bit of a different look. Hubba Bubba, Hubba Bubba! If the bike nerver runs again, I'll take the engine and put it on a coffee table as a conversational piece!
2012-02-13 New exhaust system Permalink Submitted by dcarver on Wed, 02/13/2013 - 08:50. Posted 13 February 2013 - 08:41 AM Bugnatr, on 12 Feb 2013 - 15:30, said: dcarver, on 12 Feb 2013 - 08:39, said: lnewlf, on 11 Feb 2013 - 15:23, said: Christ on a crutch!.....imagine how that thing will sound...EYHO CBX Interestingly enough, the two bikes sound very different. The KZ sounds like a chevy 350 on steroids. Not a typical 4 cyl wail or shriek, which the CBX tends to emulate. RadioHowie, on 11 Feb 2013 - 19:35, said: What with prices of used KZs running 1500 to 2500 (from the little searching I did) that there six-cylindered beastie should bring some nice scratch on Cycletrader. As Ray mentioned, parts are very spendy. This one is not for sale. Well, wait, yeah, everything has a price! Bugnatr, on 11 Feb 2013 - 20:40, said: Hey Don, I saw this CBX on the road yesterday. Damn, that header for the 6 to 1 was a work of art. Awesome! I've been wondering if I can graft this onto the Quacker.. 650 USD... Only 650?? If I had your money DC I'd buy two Phuck. Last one of fourteen. I'm now 700 USD poorer.
2013-04-19 Short Block Rebuild Permalink Submitted by dcarver on Sat, 04/20/2013 - 06:57. A big milestone has been reached on Project KrZy1300 - the engine is being reassembled! This is the point in time that having all parts bagged and tagged pays off. The white gear on the right side is a new oil pump drive gear. It came from Germany. $143 USD, if you will, and worth every penny? I tell you, she's a thing of beauty. I wonder if Ray has plastigauged the crank clearances? Check out the size of the final drive output gear. Beefy. From what I see, this engine is over-designed. Hopefully when all is said and done she won't burn oil and will be a 'runner' capabable of being ridden all over the good earth, consuming oil, making hydrocarbons, polluting the environment, and causing global warming so that WheatonFJR doesn't get cold. Wow. I think I'm getting a woody. I even like the color of the case inners. Golden Castrol. Available at a paint store near you! Powder coated cases looking good.. and Ray's new ride observes from the background. Ray, is that the new oil pump gear behind the hole in pix center? Shift forks and drum. That's all we have now - but seriously good progress has been made. Thanks Ray, for taking pix and sending them to me. reply
2013-05-05 Prepping the Rolling Chassis for Ray Permalink Submitted by dcarver on Sun, 05/05/2013 - 19:53. Ray is headed down South later this week - for Gathering of the Clan's and will pick up the rolling chassis and other parts while on the on the run. So today I got all the parts together today in prepartion. Some old parts. Worthless? Not unless you need that hardened bolt on the left side.. Fried stator waiting for rebuild.. New ignition pickup coils, one new CV diaphram, used clutch plates. Valve cover cam end caps. New since 1981.. :) Used brake pads - but serviceable. Radiator. Pipes. Way too many pipes. Rear master cylinder kit - hard to find. Oil filters, fork seals. Radiator shrouds to direct heat away from gas tank/rider. New disc brake pads. The assembled stack ready for Ray. Hope he has a V8 in the truck.. reply
2013-05-12 Rolling Chassis to LaPine Permalink Submitted by dcarver on Tue, 05/21/2013 - 19:41. After the Gathering of the Clans, we returned to get KrZy13 and all her chassis rolling parts loaded up so Mr. Ray can provide some loving touches.. Powdercoat frame, chrome, swing arm / steering head bearings / brakes... and the list grows. Loading KrZy1300 up in the truck for the ride to LaPine! ...and a Kawasaki shall lead the HondaPotaMus home! Ray and Patti's travelling road show! Almost ready to hit the road.. Parade wave, Patti! ...and they are off! Happy fixing KrZy13! reply
2013-12-17 Lower End Together and Frame Stripped Permalink Submitted by dcarver on Tue, 12/17/2013 - 19:30. Ray, Sir Ray, sent some pix of the Kz1300 Resto Project As I've been working really hard and long hours, this was much needed pick me up. Self-explanatory. Love the cross-hatch on the cylinders. Maybe this time, no oil consumption or fouled plugs? I've been working at the nuke for too long. Those studs look like control rods.. Now this is truly ART. Art that came move your butt down the road! Sure am glad Ray knows what he's doing.. ....and on to the ugliness of the chassis. Pre-teardown pix to aid reassembly. Ray, that's a custom made battery box, circa 1982, by me. Sorry bud. It's blurry, but it looks like the headlight relay I installed. Was it under the rear cowling? Part of the dual alternator/regulator set up. Feel free to clean up as needed.. ..And the stator wires need be soldered, not crimped to last. These connectors were broken apart so I could start the bike after my bud left the key in 2 pieces in the ignition switch.. Looking pretty naked! Wow. Memories. Ray, I need to think about the bag situation. Krauser 'Stars' simpy are not available anymore. A good sandblast and powder coat and the 13teen will be beooutiful again! (Nice to see grease in the steering head bearings. I remember putting it in there about 2 lives ago....) reply
2014-01-04 Back From Powder Coat Permalink Submitted by dcarver on Sat, 01/04/2014 - 18:32. Ray sent pix today of various parts and pieces back from powdercoat. Gotta love the old beat up manual in the background.... Ray ain't afraid to RTFM. For this, my first project I've 'outsourced', it's been most interesting, curious, sometimes frustrating. Frustrating not from the quality of work Ray is doing, but from not seeing, first-hand, with my own eyeballs, the project coming together. ..and for this I thank Ray for sending copious pix to feed my fix. Got to love this pix.. I need say no more. Ray, having morals, reminded me of the cost to date and estimated completion cost. It turns out that to restore a complicated engine like the KZ1300 isn't, umm, cheap. I don't care. Well, yes I do. Just not that much. I might never have an opportunity to have such a craftsman as Ray work on one of my bikes again. I appreciate his skills, experience and attention to detail. 'Nuff Said'? LOL, have to ask Ray about the tent over the microwave.. Evidently, mine was the 3,464 built. Jeesh. Ray assures me the PC looks much better than in the pix! For some unknown reason.... This pix gets my excitement at full throttle... A bare frame, waiting for engine, suspension, completion.. Pretty soon, it will be time to reassemble a motobike! Misc thoughts- Use the stock airbox or find filters to fit the carb bells? Need to decide prior to tuning. Rims and wheels - Ray's powdercoater will do the entire wheel in black for $75 per. But I kind of like the black with polished alum look provided on the spokes and the external rim area. So elbow grease and see how it looks. New tires - yes. Powder coat forks, rebuild with new seals etc. Gas tank - the inside has some light rust, IIRC Gas tank - the cap is aftermarket, not sure if it will vent properly This bike is gonna look too nice for the existing livery, which I've stated I want to keep. Wonder if I'm starting to change my mind? Seat - recover it. reply
2014-01-07 Engine Upper Assembly Permalink Submitted by dcarver on Wed, 01/08/2014 - 18:38. It's Giggle Time! I might buy another kz1300 engine just for a coffee table decoration. Was a little surprised to see the amount of hone marks. Then again I've not seen many bores freshly honed. 6 little pistons, all in a row. 6 little pistons all in the hole. Wo0w. Ray, is the horizontal channel, front side, either side of water pump, the main water passage way for each cylinder? Ray says this 6 cylinder monster engine is 'EzPZy!'. Finally - a REAL tool - the hammer. The cam lobes look delicious. Hopefully, this engine will run better than OEM new. I'm sure Ray has spent more detail and precision in this motor than QuackASucki ever did. The intake side of the house. It's easy to see why carburetors are difficult to get correct air mixture- Look at the distance difference from intake to cylinder from center cylinders to outboard cylinders. Cams in and timed! RadioHowie approves the APE manual cam chain tensioner. The stock tensioner caused many a KZ engine failure. MsDcarver just walked in the office, looked over the shoulder and said - "Are you looking at motorcycle porn again from Ray?" "You guys are like the Big Bang Theory nerds for motorcycles" edit reply