1981 Kawasaki KZ750 Resurrection

[Flyboy]

Stunning Ed

[Nessism]

Soda blasted the head. Trying to avoid grit in the blind oil galleys. The soda worked great, but it's not just a simple rinse with water and you are done aftermath. I scrubbed this head to within an inch of it's life before being confident of no more grit remaining behind. Glad it's done. Cross another thing off the list of sucky (messy) projects.

P1020016 by nessism, on Flickr

P1020015 by nessism, on Flickr

P1020014 by nessism, on Flickr

P1020017 by nessism, on Flickr

[GSX1000E]

If you haven't already found some, perhaps you could use these: http://www.ebay.com/itm/1982-Kawasak.../300784208482?

[Nessism]

Trying my hand at a little pocket porting. Just trying to smooth the sharp edges in the bowl. The short side radius was particularly poorly done and sharp.

The last two photos show the after.


P1020027 by nessism, on Flickr

P1020023 by nessism, on Flickr

P1020025 by nessism, on Flickr

P1020028 by nessism, on Flickr

[Kiwi Canuck]

I just read this entire thread from the start, all I can say is WOW, you sure do nice work and are such an inspiration to myself and many others on this forum.

I remembered that you discussed your spray painting setup in this thread and once I'd read that part I couldn't stop, so I just re-read the whole thing, I'm tired just thinking of all the work you've done.

I've just purchased a DeVilbiss spray gun kit and a Campbell Hausfeld Filter/Dryer unit and looking at what else I need, just trying this out to see if it's something I can get the hang of.

http://www.eastwood.com/devilbiss-auto-paint-and-touch-up-system.html?fee=5&fep=2324&utm_content=12505&utm_campaign=Shopzilla01&utm_source=Shopzilla&utm_medium=Merchant-Centre&SRCCODE=1SE1532

I have a small 20 gallon Snap On brand compressor, Costco special, that probably gets max 5CFM at 30PSI, so I'll probably need to go bigger.

What compressor do you have? and does it serve your purpose or would you recommend something else.

Thanks again for your fantasic reports.

David

[Nessism]

I just read this entire thread from the start, all I can say is WOW, you sure do nice work and are such an inspiration to myself and many others on this forum.

I remembered that you discussed your spray painting setup in this thread and once I'd read that part I couldn't stop, so I just re-read the whole thing, I'm tired just thinking of all the work you've done.

I've just purchased a DeVilbiss spray gun kit and a Campbell Hausfeld Filter/Dryer unit and looking at what else I need, just trying this out to see if it's something I can get the hang of.

http://www.eastwood.com/devilbiss-auto-paint-and-touch-up-system.html?fee=5&fep=2324&utm_content=12505&utm_campaign=Shopzilla01&utm_source=Shopzilla&utm_medium=Merchant-Centre&SRCCODE=1SE1532

I have a small 20 gallon Snap On brand compressor, Costco special, that probably gets max 5CFM at 30PSI, so I'll probably need to go bigger.

What compressor do you have? and does it serve your purpose or would you recommend something else.

Thanks again for your fantasic reports.

David

Hi David,

Thanks for the props. I've learned a thing or two through the years, mostly by making mistakes. At any rate, I've painted quite a bit using a 20 gallon 2 hp (15 A) compressor and a small touch up spray gun. I wouldn't try to paint a car using such a setup, but a motorcycle is no problem. I currently have a huge monster of a compressor (80 gallon and 5 hp), having acquired it through a partial trade. Didn't go looking for such a unit, but have to admit it comes in handy.

If you have any specific questions about painting or whatever, don't hesitate to PM me.

[Nessism]

Did a little more work on the head. Painted it of course, and touched up the valve seats with a Neway cutter.

Less than thrilled about how the seats look (mostly the intakes). In particular, the seat width is wider than ideal. The seat width isn't the most consistent either. Kawasaki apparently isn't overly particular about such things. I'm pretty sure this isn't a big deal, but it sort of bugs me. I think Suzuki is better about things like this, or at least my GS1000 engine didn't have this issue.

P1020057 by nessism, on Flickr

P1020061 by nessism, on Flickr

P1020062 by nessism, on Flickr

P1020063 by nessism, on Flickr

[TeamDar]

If you use a 75 degree and a 15 degree seat cutter you can narrow the 45 degree seating surface to any width you want and make it consistent as well.

[Nessism]

If you use a 75 degree and a 15 degree seat cutter you can narrow the 45 degree seating surface to any width you want and make it consistent as well.

75 and 15 are Suzuki's angles. I have cutters for those. Kawasaki uses 30 and 60, which I don't have. I'm contemplating purchasing these sizes but because of how the seat sits down in the head I'm not sure I can get in there with Neway's. Need to do some more study.

[Nessism]

Okay, some progress to report.

I've been stuck mentally with the head because the intake valve seat width was just not right. Service manual calls for 1.0mm max width, but one side of the intake valves were at 1.5mm and the other 1.0. Kawasaki apparently was really sloppy with their machine work. Was trying to figure out what Neeway cutters to order when I decided to see that a 75* Suzuki cutter would do. Low and behold, it was the perfect size to narrow down the seat width. Learned that the valve seat angles for this head are not consistent because the 75* cutter only contacted the seat on the area as needed. Call it a gift from God on Christmas day. Happy now!

P1020105 by nessism, on Flickr

P1020104 by nessism, on Flickr

[SVSooke]

And the lesson of the day is Suzuki knows best

[TeamDar]

If you use a 75 degree and a 15 degree seat cutter you can narrow the 45 degree seating surface to any width you want and make it consistent as well.

That's what I tried to tell you....

[Nessism]

That's what I tried to tell you....

Yes you did! The 45 is fine, but the lower cut, down in the port, is not even around the seat. The 75 didn't even touch the seat all the way around. Basically, it just trued up the lower cut.

I'm thinking that Kawasaki doesn't touch this lower cut and the shape is defined prior to installing the seat into the head. I suspect they install the seat into the head and touch up the 45 and the top cut only.

[Nessism]

Not much to report other than decided to stay with the stock bore size. Sold the big bore kit for a good price. Bit the bullet and bought new OEM rings from Z1. Their price was cheaper than others I could find, but not cheap overall - $50/hole just for rings. Going to have the valves touched up then the head can go back together.

[ron bayless]

I am curious.How much have you spent on this bike including purchase price? 3,000? And I am also curious why you did all this with a kawasaki.Is it because it is something different? You are an excellent builder.The bike will be perfect when you are done.