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Old 01-13-2013, 07:03 PM   #16
Beezer
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Location: Anchorage, formerly Spenard (hub of the universe)
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here....

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

http://www.motorcyclistonline.com/fe...wasaki_2300cc/


there was a better site a few years ago (by the builder?) but I can't find it
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Old 01-13-2013, 07:04 PM   #17
telejojo
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Location: Huntsville Ala. foothills of the Smokey's
Oddometer: 450
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.
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Old 02-22-2013, 08:51 AM   #18
dcarver OP
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Awesome Kz1300 Beezer!

Quote:
Originally Posted by Beezer View Post
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:

Your project turned out great! WooHoo for you!
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Old 02-22-2013, 09:05 AM   #19
dcarver OP
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Before the crank could see daylight..

Ray is tearing her down!


Ray built this cool engine stand.


I wonder what we'll find inside...


Slight corrosion on aluminum.







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.


x


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.



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!





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Old 02-22-2013, 08:41 PM   #20
sailah
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Location: Turning expensive metal into scrap
Oddometer: 5,504
I diggit. Love seeing motors apart and then back together
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Old 02-24-2013, 04:41 PM   #21
telejojo
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Location: Huntsville Ala. foothills of the Smokey's
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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.
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Old 09-01-2014, 02:54 AM   #22
nevgriff64
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Any further updates on this one?
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Old 09-22-2014, 08:08 PM   #23
dcarver OP
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Quote:
Originally Posted by nevgriff64 View Post
Any further updates on this one?
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..
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Old 09-22-2014, 08:28 PM   #24
nevgriff64
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Quote:
Originally Posted by dcarver View Post
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..
No worries, watching with interest.
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Old 11-23-2014, 11:24 AM   #25
dcarver OP
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2012-12-10 BlockOff

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....

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Old 11-23-2014, 12:01 PM   #26
flemsmith
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Location: Apache Junction, Az
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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
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Old 11-23-2014, 12:40 PM   #27
nouhlaC
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Location: Nor Cal
Oddometer: 18
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.
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Old 11-24-2014, 03:13 PM   #28
dcarver OP
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Ray responds with what the parts are...

I have now clue what this is... .7.jpg


31.jpg


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.

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Old 11-24-2014, 03:14 PM   #29
dcarver OP
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2012-12-13 More Disassembly

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. no


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...

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Old 11-24-2014, 03:16 PM   #30
dcarver OP
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2012-01-01 Rods off Crank

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..

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