76 KZ 750 Engine Rebuild

akcender

New Member
Alright, heres what happened. I was a foolish teenager that didnt really know anything about bikes other than they had 2 wheels and an engine. For some, this seems to be enough to start on a a project and for a while i was one of those people. This all changed after disassembling the engine from my 1976 Kawasaki KZ750 which, i must say, was (and still is) in immaculate condition. After i split the cases, i was hit with a realization that i really didnt know anything about bikes. So much so, i threw out the kickstart spring guide thinking it was an electrical conduit connector (my first and hopefully my last stupid mistake). This led to reading everything i could find about the bike over the winter months so i could competently re-assemble this engine. Now that i have started the re-assembly process i am finding that it really is quite simple, but, i am very glad i took the time to read up on how this thing goes back together. Well, after reading that over again im not sure why im telling you all this but anyway, heres some pictures from last summer and some new ones.


Here shes sits after i bought her
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You all know whats going on here
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My very tight workspace (though i am very grateful for it, thanks dad!)
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Just before i pulled the engine (I did this alone, i was 16 at the time, i absolutely destroyed my back. Please, do yourselves a favor and get help when you need it.)
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There was some rusting in the cylinders, nothing major, just on the surface. Planning on honing them right after i get the bottom end back together. If there is any damage due to the rust, i have full access to a machine shop and i plan to bore it over to the next dimension up.
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Now for some updated pictures
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Dry fit of the cases, i had applied the gasket and planned on scrubbing them by hand but i then decided to further strip them down and soda blast them. Sorry for the crappy cell pics, ill get better ones when i start blasting.
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And just one last one to show off what you can find in Toronto...
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Progress today,

Starting removing parts, lots of pictures to reference back to for re-assembly.
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What my small workspace has turned into...
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More disassembly today, also had the first mishap.

Removed cam chain tensioner mount
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Removed crankcase breather assembly, here comes the mishap...
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When removing what i assume is an oil guard for the breather system, one of the bolts broke flush with the surface
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So, i guess its time to ask about removing broken bolts from inside an engine. Anyone...Anyone...
 
Easy out was a no go. Had to drill and tap it again. I think it turned out alright. Im very glad that it is not a very critical bolt, the repair should work just fine for what it is.
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Picked up some ZEP Calcium Lime Rust yesterday and threw my case bolts in some. The results really are amazing, clean as a whisle.
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Got the cases fully stripped and ready to go.
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Soda blasting coming soon!!
 
Started blasting today, cant say im totally impressed with the results but near the end i think i picked up a technique and it started going pretty well.

Heres what the setup looked like, how i had the gun working and so on...
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Very important to WEAR A RESPIRATOR WHEN DOING THIS, it is really bad for you to breathe a lot of this stuff in.


Heres how it looked before... (sorry, not the best picture)

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And after, 6 boxes of soda later...

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I think most of the grime is pretty much baked on the engine case, it just wouldnt come off. I am painting the cases black so really, im just trying to get all the major crap off to prep for paint. If anyone can offer any tips to improve the results, or some paint prep tips that would be great. Thanks for checking in!
 
I would love to know how they take engine cases beyond what you were able to do with your set up. From what I've read, the more powerful soda blasters give the engine cases and other parts that brand new "casting" look. This is something I may be doing myself soon so I'm just as interested as to what others would recommend.
 
Back at it!

After a long cold winter in Toronto, I can finally work outdoors again. Right now the plan is to get the cases prepped for sandblasting on Tuesday. I will be taking them to my school and using their blasting cabinet, I was not happy with the results of my sodablasting adventure so hopefully this will get me what I'm looking for. I know that I will be painting the cases black so if anyone knows a good black, tough, heat resistant paint I would love to hear from you. Anyway, I'll have more to say tomorrow after i finish prepping the cases, take care for now.

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The next day...

Before I could start masking, I had to remove all of the cylinder studs. This turned out to be easier than I expected because none of them snapped! Basically, I just used the 2 nut method and a cheater bar to break them all loose.

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Next step was masking. For the cylinder mating surface I used one layer of vinyl electrical tape as a base, this took way too long to do and I convinced myself that it wasnt necessary. Consequently, all the other surfaces are just lined with 3 layers of duct tape.

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And the obligatory kitchen counter shot...
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Off to sandblast today. Hopefully there will be some updates here by the end of the day.
 
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