Author Topic: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.  (Read 50925 times)

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Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #275 on: July 04, 2020, 07:01:39 PM »
Full steam ahead Terry !  :) Somewhere down the road,if the pistons needed new rings,are they still available ?

Thanks G, yep, surprisingly, you can, as Arias still exists (part of the Carillo organisation now) Wiseco still make the 83mm piston kits (so hopefully the rings will be the same) and I think MTC and APE do them as well? Not to mention that there is a ton of NOS parts available from Ebay, APE, etc.

I don't think I'll be clocking up enough miles on any of my bikes (apart from my Yamaha FJR1300, which has already done 147000 miles on the original engine, with no "engine out" work, I've replaced some coolant hoses and thermo fan, but it hasn't even had a clutch job) so I don't think I'll get to the stage where I wear anything out, not including the possibility of catastrophic failure caused by my own mechanical ineptitude. Oh well, that's where Ebay is your friend............ ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #276 on: July 04, 2020, 08:50:28 PM »
Full steam ahead Terry !  :) Somewhere down the road,if the pistons needed new rings,are they still available ?

Thanks G, yep, surprisingly, you can, as Arias still exists (part of the Carillo organisation now) Wiseco still make the 83mm piston kits (so hopefully the rings will be the same) and I think MTC and APE do them as well? Not to mention that there is a ton of NOS parts available from Ebay, APE, etc.

I don't think I'll be clocking up enough miles on any of my bikes (apart from my Yamaha FJR1300, which has already done 147000 miles on the original engine, with no "engine out" work, I've replaced some coolant hoses and thermo fan, but it hasn't even had a clutch job) so I don't think I'll get to the stage where I wear anything out, not including the possibility of catastrophic failure caused by my own mechanical ineptitude. Oh well, that's where Ebay is your friend............ ;D

Well in the past, when I assembled certain engines with good seating rings(they didn't use any oil and no smoke)after cleaning off the original rings and ring lands in the pistons and reinstalling everything the engines didn't have a sealing(used a little oil,blowby) set of rings anymore.I needed to have a machinist give a very light hone to each cylinder(enough to give even crosshatch to each cylinder) with a 4-stone quality hone and then new rings were required to get them to seat-in properly:that has been my experience.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline 754

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #277 on: July 04, 2020, 09:09:24 PM »
You surprised me Terry, trying to get a cylinder on without piston blocks..  that made me chuckle..
 The shims on hose clamp for ring compressor, I used beer can metal.. too thin..I got part of that stuck between a ring and the wall , on the last 2 pistons, had to pull it up..
 I have a question about gas ported pistons, do they gum up the rings on the street ?
 At least with used rings you can get it running, try it out while you wait for rings..
 Gonna be a Fun motor. .. clay your pistons, check without headgasket or a few 1/2 thickness shims to make sure pistons are clearing head.. no shortcuts in this stuff..
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Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #278 on: July 05, 2020, 03:15:49 AM »
Thanks G (I keep calling you "G" because I don't know your name, but if you want to keep it private, I understand) These pistons were like new, no carbon build up at all in the ring lands, and the rings feel sharp. The seller said the bike only did a couple of runs, and I have to believe him, the cylinders all still had good hone marks on them, so I couldn't see any point in taking out my old 4 stone hone and doing what was already done, they're all pretty much new.

I've got to buy some piston blocks Frank, where can I get some? I was happy with my home made ones, because I was able to get all 4 pistons into the cylinders in two stages, without removing the blocks. I may need to do something drastic as I attempted to use the Web cams with the Z1 head and it was no bueno, I couldn't turn the crank without the valves touching. OK, so I took those cams out and tried the GPZ1100 cams which have less lift, but same/same, a quarter of a turn, and the valves were hitting. Bugger. Another option is to cut a thicker copper base gasket, I think I'll try a version of Frank's trick of using some thick washers, but between the head gasket and the head, to see if that gives me enough clearance, if it does, I'll go find a nice chunk of copper sheet and make me a nice thick base gasket.

Now I do have another NOS Eagle crank that's been welded and balanced, that apparently has a slightly shorter stroke that the seller said was "suited to use with big block race engines". I didn't use it because it has a 16 tooth cam chain sprocket meant for a Hyvo chain, and I wasn't sure whether it would work in the earlier engine, but it might be OK, and I did buy 32 tooth cam sprockets and cam chain tensioners (no sprockets, just rubber guides) and I may be able to use the GPZ head, and the alternator/starter clutch that didn't fit the Z1 crank will go right on. Plenty of options......

Anyway, I shoved the head in the ultrasonic cleaner for an hour @ 50 deg C and it came out sparkling clean. I haven't decided completely if I'll paint it black or silver yet, I quite like the black head on the silver engine, but regardless, the paint is pretty poor, so will need some stripping and re-doing. I might need to get it bead blasted off, but I'll try paint stripper first, which will save me having to remove the valves and springs etc. Anyway, more tomorrow, stay tuned, something interesting might actually happen! ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline 754

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #279 on: July 05, 2020, 07:36:43 AM »
You can maybe buy the blocks but just get 3/4 or 1 inch aluminium mill a long slot , leave one end closed, or drill and saw.
 I think when I last did mine I may have used plywood or aluminium strips or bars.. flat one piece is better, wont move around. .
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Kelowna B.C.       Canada

My next bike will be a ..ANFOB.....

It's All part of the ADVENTURE...

73 836cc.. Green, had it for 3 decades!!
Lost quite a few CB 750's along the way

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #280 on: July 05, 2020, 10:17:25 AM »
Terry,My name is Bill.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline ekpent

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #281 on: July 05, 2020, 02:05:27 PM »
Terry,My name is Bill.
Hi Bill ! Sorry that I did not know your real name either.

Offline Alan F.

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #282 on: July 05, 2020, 05:30:20 PM »
Terry,My name is Bill.
Hi Bill ! Sorry that I did not know your real name either.

Hi Bill.  We all sure do get around.

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #283 on: July 05, 2020, 07:50:40 PM »
Hi everyone  :)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #284 on: July 06, 2020, 03:17:07 AM »
Thanks Bill, I can understand if folks on the interwebs want to stay private, but I feel a bit weird when I can't address someone by their name. After 43 years in the Army when most of us had a nickname, I learned that a black (Aussie Aboriginal) mate of mine who's nickname was "Tracker" when we served together, actually had a first name, (Patrick) and I apologised to him for calling him by his nickname, but he told me that he was more than happy for his mates to keep calling him that, because it was never meant as a racial slur.

Thanks for the info regarding the piston blocks frank, I've got some thick plywood out in the garage so I'll make a couple for the inevitable top end tear down.......... ;D     
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #285 on: July 06, 2020, 09:01:19 AM »
Thanks Bill, I can understand if folks on the interwebs want to stay private, but I feel a bit weird when I can't address someone by their name. After 43 years in the Army when most of us had a nickname, I learned that a black (Aussie Aboriginal) mate of mine who's nickname was "Tracker" when we served together, actually had a first name, (Patrick) and I apologised to him for calling him by his nickname, but he told me that he was more than happy for his mates to keep calling him that, because it was never meant as a racial slur.

Thanks for the info regarding the piston blocks frank, I've got some thick plywood out in the garage so I'll make a couple for the inevitable top end tear down.......... ;D   

Well Terry,
I was on here during times(still am..)when I didn't feel like I qualified to be a member as i don't presently have an 'up and running' sohc4.The $ thing.. I've moved a number of times and been down on my luck quite a bit.I really like this forum and don't want to give it up.You're a real good group of friendly folks and I've missed you.Plenty of collective knowledge here and you have a pleasant way of sharing it.  :)
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline ekpent

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #286 on: July 06, 2020, 05:21:45 PM »
Thanks Bill, I can understand if folks on the interwebs want to stay private, but I feel a bit weird when I can't address someone by their name. After 43 years in the Army when most of us had a nickname, I learned that a black (Aussie Aboriginal) mate of mine who's nickname was "Tracker" when we served together, actually had a first name, (Patrick) and I apologised to him for calling him by his nickname, but he told me that he was more than happy for his mates to keep calling him that, because it was never meant as a racial slur.

Thanks for the info regarding the piston blocks frank, I've got some thick plywood out in the garage so I'll make a couple for the inevitable top end tear down.......... ;D   

Well Terry,
I was on here during times(still am..)when I didn't feel like I qualified to be a member as i don't presently have an 'up and running' sohc4.The $ thing.. I've moved a number of times and been down on my luck quite a bit.I really like this forum and don't want to give it up.You're a real good group of friendly folks and I've missed you.Plenty of collective knowledge here and you have a pleasant way of sharing it.  :)
  Careful Bill.I said some nice things about Terry on another thread and now you are giving him a compliment also. Holy Crap he's gonna think he is likeable or something and be totally unbearable to be around. Probably buy another Kaw project just to keep our attention  :D :D

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #287 on: July 06, 2020, 05:57:04 PM »
Thanks Bill, I can understand if folks on the interwebs want to stay private, but I feel a bit weird when I can't address someone by their name. After 43 years in the Army when most of us had a nickname, I learned that a black (Aussie Aboriginal) mate of mine who's nickname was "Tracker" when we served together, actually had a first name, (Patrick) and I apologised to him for calling him by his nickname, but he told me that he was more than happy for his mates to keep calling him that, because it was never meant as a racial slur.

Thanks for the info regarding the piston blocks frank, I've got some thick plywood out in the garage so I'll make a couple for the inevitable top end tear down.......... ;D   

Well Terry,
I was on here during times(still am..)when I didn't feel like I qualified to be a member as i don't presently have an 'up and running' sohc4.The $ thing.. I've moved a number of times and been down on my luck quite a bit.I really like this forum and don't want to give it up.You're a real good group of friendly folks and I've missed you.Plenty of collective knowledge here and you have a pleasant way of sharing it.  :)
  Careful Bill.I said some nice things about Terry on another thread and now you are giving him a compliment also. Holy Crap he's gonna think he is likeable or something and be totally unbearable to be around. Probably buy another Kaw project just to keep our attention  :D :D

You hate to have it 'go to his head' ?  Lol
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline spotty

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #288 on: July 07, 2020, 01:05:28 AM »
as long as it doesn't go to his liver......
i blame Terry

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #289 on: July 07, 2020, 01:08:25 AM »
as long as it doesn't go to his liver......

Exactly
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #290 on: July 07, 2020, 05:53:47 AM »
Ha ha, thanks guys, I'm lucky that I had any form of self importance kicked out of me during my first few years in the Army by unforgiving Vietnam vets, so I've been relatively humble ever since. I've always loved mechanical things, and pretty much anything with an engine in it in particular. My only major problem is, I can't stop myself from adopting poor unwanted motorcycles, and trying to give them a better life. The more I think about it, the more I realise that I'm like the "Mother Theresa" of Motorcycles.

I imagine that someone will change that to "Mother F.....", but only in jest, we are a friendly bunch. I only wish you lived nearby Bill, I could loan you a bike or two to bring back from the dead and ride until you got sick of it, or me, I have more bikes here than I know what to do with, Spotty's K7 is still on my trailer in my driveway (under 2 bike covers, I'm not a monster!) a year(?) after we swapped projects.

Anyhoo, today was a good day, my new air compressor for the "Sheltered Workshop" arrived (no pics, you've all seen an air compressor) so I had to take an extended lunch break from my "Working at home" regime to do the final assembly and test it, by running the new 50 foot hose up to the carport and pumping up the tyres on the wife's Hyundai, probably for the first time in a couple of years. Surprisingly they were all in the mid 20 psi range, which is fine for a little car that rarely does any long trips, but I inflated them back up to 32 psi, so I don't have to check them again for another couple of years. Korean cars, they don't need no love.......... Now a 50 foot hose is a pain in my little workshop, so I hung it up and found a 6 foot hose with a duster gun in my garage that I'll use for keeping the bugs out of my Kawasaki engines. (and my CB750 engine when I fix the gearbox next)   

I tried to find a nice thick sheet of copper for an extra thick base gasket, but no-one would sell me a piece the size I need, and the price for a complete sheet (that I don't need) would buy another couple of air compressors and a new battery for my BMW K100RS, I had a re-think, and decided to go for aluminium. I've seen aluminium head and base gaskets (the head gaskets in the 1100 engine were aluminium) so I rang my local aluminium stockist, and he said he'd sell me half a sheet of milled 3mm thick (1/8") aluminium (80 bucks) and for an extra 16 bucks would cut it into whatever sizes I wanted, so I asked him to cut me as many 8" (200mm) x 18" (440 mm) pieces as he can, and I'll find a use for what I don't use, while having some spares if I fcuk one up. It's a bit of a gamble as 3mm might not be enough, but with Melbourne being locked down again from midnight tomorrow night, I don't really have a choice, plus I think I've got some big pieces of 1mm thick sheet out in my garage somewhere?

The battery for the BMW arrived at the same time, it weighs 22 pounds, and would be around the same size as the one in the Hyundai. Bloody hell, I was really worried I'd bought the wrong one until I googled the Motobatt HD (Black edition, don't ya know?) part number, and apparently it fits all BMW K100's, in fact it fits pretty much every BMW bike from 1970 to 1993, inclusive. It was also the most expensive bike battery I've ever bought, so I hope it lasts me as long as I keep the bike, which I need to keep forever, as I'm a member of the BMW Club, which allows me to get cheap "Club Permits" for all of my bikes over 25 years old. (most of them) Once Spotty puts up my new garage I'll move my 4 bikes (including the BeeEm) in storage back home, so I can attach them to battery tenders to keep them alive as long as possible. That probably won't be until Spring now that Melbourne has been locked down for 6 weeks from midnight tomorrow, but that's OK, they should all last with an occasional metropolitan freeway triangle blast (no country rides allowed) until then.

I've taken tomorrow off. Coincidentally it's the wife's birthday, I haven't told her about me taking the day off yet, but being that it's my last chance to do 100(+) mile ride #14 for the next 6 weeks, I'm gonna surprise her and buy her some McDonalds pancakes for her Birthday breakfast before I break the news to her that I'm off for a sanity ride before lockdown. Hopefully I'll look humble enough that she doesn't stab me in the eye with a syrupy plastic fork.......... ;D 
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline ekpent

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #291 on: July 07, 2020, 06:06:10 AM »
 Amazing how many bikes a CB750 battery fits. So far this year I have had it in CB750 K's and F's, Suzuki GS1000,Kawasaki 1975 900 Z1b, and a CB900F. Maybe that should be my new rule "if a 750 battery doesn't fit I don't want it"   ;D

Offline grcamna2

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #292 on: July 07, 2020, 11:27:32 AM »
Terry,I will most certainly enjoy taking you up on that offer:I say this hoping to spend time in Australia in the future.
I've heard many good things about your country and the different Australian women I've noticed in my past(possibly 8..)lets me see a bit of how open and kind many of you must be.
75' CB400F/'bunch o' parts' & 81' CB125S modded to a 'CB200S'
  I love the small ones too !
Do your BEST...nobody can take that away from you.

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #293 on: July 08, 2020, 02:15:02 AM »
Amazing how many bikes a CB750 battery fits. So far this year I have had it in CB750 K's and F's, Suzuki GS1000,Kawasaki 1975 900 Z1b, and a CB900F. Maybe that should be my new rule "if a 750 battery doesn't fit I don't want it"   ;D

That is true Eric, you, with 3 times as many bikes as me need to keep to that rule, sadly I have so many different bikes of different makes, apart from the XS650, Z1, KZ1000 and CB750's, they all use annoyingly different size batteries. Oh well, I can't take it with me....... ;D 
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline spotty

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #294 on: July 08, 2020, 02:53:52 AM »
the battery i bought for the zzr which has been sitting on a shelf unfilled since i got itwas last week pressed into service, filled it with acid and put it in the bike...or not. its about a cm too long and wide....bollocks, should have test fitted it BEFORE i filled it with acid

all was not lost, it fits the hellbound hyosung i've got disabled in my yard and behold the hyosung turns over and has basic electrical functions. i keep forgetting to get the jerry can filled so i can see if it will actually start and i can get rid of it

still leaves me with no battery for the zzr, why can't there be ONE battery for all bikes
i blame Terry

Offline bear

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #295 on: July 08, 2020, 03:44:50 AM »
why can't there be ONE battery for all bikes

“One Ring Battery to rule them all,
One Ring Battery to find them,
One Ring Battery to bring them all
and in the darkness bind them.”
 ;D ;D ;D ;D
The older I get the faster I was.

Offline Terry in Australia

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #296 on: July 08, 2020, 04:58:11 AM »
why can't there be ONE battery for all bikes

“One Ring Battery to rule them all,
One Ring Battery to find them,
One Ring Battery to bring them all
and in the darkness bind them.”
 ;D ;D ;D ;D

Very good Brian, especially astute, considering it was the "Ring of power"........ ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

"Crazy is a very misunderstood term, it's a fine line that some of us can lean over and still keep our balance" (thanks RB550Four)

Offline PeWe

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #297 on: July 08, 2020, 05:43:00 AM »
The smallest will fit all bikes as long as it is 12V and posts correctly placed. There are + at left or right....
« Last Edit: July 08, 2020, 07:42:02 AM by PeWe »
CB750 K6-76  970cc (Earlier 1005cc JMR Billet block on the shelf waiting for a comeback)
CB750 K2-75 Parts assembled to a stock K2

Updates of the CB750 K6 -1976
http://forums.sohc4.net/index.php/topic,180468.msg2092136.html#msg2092136
The billet block build thread
http://forums.sohc4.net/index.php/topic,49438.msg1863571.html#msg1863571
CB750 K2 -1975  build thread
http://forums.sohc4.net/index.php/topic,168243.msg1948381.html#msg1948381
K2 engine build thread. For a complete CB750 -75
http://forums.sohc4.net/index.php/topic,180088.msg2088008.html#msg2088008
Carb jetting, a long story Mikuni TMR32
http://forums.sohc4.net/index.php/topic,179479.msg2104967.html#msg2104967

Offline spotty

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #298 on: July 08, 2020, 06:22:40 AM »
what the hell are you lot on about ?
i blame Terry

Offline bear

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Re: Terry's NEW big Kawasaki build, the "Lockdown 1428" special.
« Reply #299 on: July 08, 2020, 06:01:20 PM »
what the hel ;D ;Dl are you lot on about ?

 ;D ;D ;D ;D
So your not a Tolkien fan Spott? ;D
The older I get the faster I was.