Project KZ1300

[Tanker]

Looking forward to seeing the efforts of your final push Ray.

Good luck sourcing those final bits guys!

Don must really be itching to get it over the goal line.

 

[dcarver]

A little out of order.. been busy.

Ray determined that the outer cases were too pitted to sand then polish the pits out. Not enough material.
So off they go for powder coat.

Ray's getting good at applying the magic green tape..


The rest of the engine sits, ready for install.


Looking good.

The carbs got new internals and Ray polished them up a bit..

That's it for now...

 

[dcarver]

2014-01-21 Parts Powdercoated

Permalink Submitted by dcarver on Mon, 04/07/2014 - 12:32.

Reassembling is definitely the name of the game these days!

Swing arm gets new bearings.



Drive shaft is in good shape.



Steering head bearings. For as much use as the bike will get, All Balls is just fine, thank you.



Swing arm attached to frame.



Final drive in place.



Triple trees installed.



Check out the awesomely huge fork diameter!



Center stand getting attached.



Project KZ1300 is looking Good!

 

[dcarver]

2014-01-25 Prep Frame for Engine

Permalink Submitted by dcarver on Mon, 04/07/2014 - 12:53.


Now then, Ray wonders..

How the hell do I stuff that engine back into this frame?

Let's see, got me some bungee cords, a milk crate, and ty-downs. Ready to Rock!



Protect all the shiny pieces..



Uh-Oh, where did that splooge come from?

 

[dcarver]

2014-02-25 Fuel Tank Ugliness

Permalink Submitted by dcarver on Mon, 04/07/2014 - 13:11.

From Ray -

The tank doesn't have a little rust it has ALL rust. Will start the cleaning process ASAP. Fill caps are not available from Kawi and the valve isn't either. The guy in Germany has repops for reasonable and has OEM for around 200 euros . The valve on the tank isn't correct . Looking in the manual it should be an electric one. should I try to find the original type or stick with what we have. What's here will work but the filter screen is junk so an inline filter will be required.

The fuel level sending unit is non functional according to my meter. Do you want it to work????
That's it for now.
---

Eeegads and little fish eggs - this sucks.








"After lots of cleaning the sending unit show good on the ohm meter. The tank is soaking full of vinegar. I've had pretty good luck cleaning that way. I've had poor results trying to use the epoxy sealers. I got the fuel valve cleaned up and it seals well."

Note to self - ask Ray if he's done a vent test on the tank.. always had trouble with the tank venting correctly.

That's all the updates for now.. lunch time is over.

 

[Tanker]

Awesome stuff Don and Ray!!

I've been looking forward to another update and this puts a smile on my face.

Thanks.

 

[Niehart]

Awesome stuff Don and Ray!!
I've been looking forward to another update and this puts a smile on my face.

Thanks.

+1

 

[TomInPA]

Don, I wonder if the rust in the tank could be removed though electrolytic galvanic rust removal. Articles describing this are all over the internet, but the basic idea is to restore the oxidized metal with new reduced iron using electrolysis. Filling the tank with a solution of sodium carbonate (washing soda) and inserting a sacrificial steel anode on the positive lead of a low-amp battery charger, and clip the negative leads to the tank should replace the rust with a serviceable steel coat. It would work if the rust is not too deep or penetrates the whole tank.

Link to article using electrolytic rust removal on a motorcycle fuel tank This kind of project is ideal for geeks like us.

 

[FJRay]

The vinegar worked well. tank looks good inside.

Got airbox and battery tray today. The radiator and fan are now installed. working on wiring that was already apart so it's slow going trying to get things routed. Wheels will be back from paint soon so it will be a roller.

Should be ready for smoke or shrapnel soon.

I'll get more pictures to Don and he still has some that haven't been posted.

 

[Bustanut joker]

Do us a favor and don't send shots of him naked with the chickens again...I'm still sick over that ****!

 

[beemerdons]

Do us a favor and don't send shots of him naked with the chickens again...I'm still sick over that ****!

Speak for yourself ya *******, I've already printed and framed those pictures! JSNS!

 

[dcarver]

Thanks for the nice words everyone. Tom, I gotta try that technique someday. I have a small 8 horse Brigs with a bad tank..

..and now back to the story...

2014-02-28 - Engine In Frame

Permalink Submitted by dcarver on Mon, 04/07/2014 - 19:53.


Alrigghty then, today's the day to get an engine into the frame!

Ray has all the goodies, including a hoist!


Ray also rebuilt an 87 XR600 engine for me. It's the little engine behind the SensousSix.


The suitcase is full of new XR600 parts. The sling is full of new KZ1300 parts!

CarverTape everywhere to prevent scratching the new powdercoat..


Presto Poof, frame installed! It's all easy when sitting just looking at pix.. GREAT job Ray!


Wow, looking more like a motobike all the time now.




Kinda wish the covers could have been buffed out, but the pitting was too deep.


..and there you have it, one engine in one frame!

 

[HotRodZilla]

Holy ****...Finally!!

 

[Niehart]

That motor is a freaking beast. Coolio!

 

[escapefjrtist]

That motor is a freaking beast. Coolio!

For sure!

Looking good DC, that mechanic you got there is a keeper!

--G

 

[juniorfjr]

That motor is a freaking beast. Coolio!

For sure!

Looking good DC, that mechanic you got there is a keeper!

--G

A keeper, as in don't leave it out in the weather. Got it.

 

[dcarver]

That motor is a freaking beast. Coolio!

For sure!
Looking good DC, that mechanic you got there is a keeper!

--G

A keeper, as in don't leave it out in the weather. Got it.

..and once every month he gets a bath!

 

[juniorfjr]

That motor is a freaking beast. Coolio!

For sure!
Looking good DC, that mechanic you got there is a keeper!

--G

A keeper, as in don't leave it out in the weather. Got it.

..and once every month he gets a bath!

I meant the bike is a keeper, but Ray is too. But I think monthly baths are a little much for him.

 

[dcarver]

2014-03-02 Exhaust On

Permalink Submitted by dcarver on Sat, 04/12/2014 - 11:50.


Ray is making seriously good progress.

Tach drive assembly, thermostat, wiring harness installed.

I wonder if the master cylinder is going to work. I don't recall right now, but either the master or slave are parts unobtanium.



This pix reminds me to email Ray - the alternator stator wires need be crimped then soldered. KZ1300's are notorious for frying stators after the connections get dirty.



The belly of the beast!



The front side. The water inlet looks like Ray polished it!

Exhaust installed! DG 6 into 1. Man oh man, it looks bitchen!

That right there is motobike ****!



.. more to follow

 

[lnewlf]

I think I just wet myself