1981 Kawasaki KZ750 Resurrection

[tkent02]

Member of the year Rustybronco (Dale) helped me select some suitable chassis paint and primer, which is inbound as I type.

Which paint/primer are you going with?

[Nessism]

Which paint/primer are you going with?

Transtar epoxy primer...http://www.ebay.com/itm/350772839591...84.m1497.l2649

Nason black urethane...http://www.ebay.com/itm/181280759145...84.m1497.l2649

Need to get some semi gloss next, or some flatting agent for the Nason. Have a few parts that need semi gloss.

[rustybronco]

I was in my local autoparts last night picking up a few quarts of trans fluid. Low and behold what do they have in stock? Nason's paint system. If you can't find that flattening agent locally let me know.

Tom, that Transtar mixes 1:1. You get a 1/2 of material for around (less than?) the same price as 1 quart of PPG's DPLF and a pint of the appropriate activator. ($70'ish IIRC)

No induction time, tintable, 72 hour pot life and very close to DPLF's % of solids.

One of my local body shops uses Transtars products and can't say enough good things about them.

[tkent02]

Did a little blasting today...

Ed, do you want these pieces powder coated or are you in a hurry to get it done??

[blowerbike]

Ordering up parts, paint, and various supplies to keep this project moving forward. Member of the year Rustybronco (Dale) helped me select some suitable chassis paint and primer, which is inbound as I type.

Finding a decent stock master cylinder has proved difficult, since everything on ebay looks hammered. Found a late model EX650 master for $35 shipped so grabbed that instead. Thinking I might upgrade the hand controls too, since my current units are heavily weathered. The RH side should be easy enough; there are only three wires to deal with (kill switch, starter, and ground). The LH side is going to require more study.

is the 650 master 1/2" or 5/8" bore?
is you have dual disc....you may not be happy if it's a 1/2" bore.

[Nessism]

Ed, do you want these pieces powder coated or are you in a hurry to get it done??

Thanks for the offer Tom, but I want to do the painting myself. Would love to set up powder coating like you did...some day, but for now it's going to be liquid paint.

[Nessism]

Measured the cylinders last night with a bore gauge. Stock bore size is 66.0mm and service limit is 66.1mm, with no more than .05mm difference between the three measurement positions speced (total of six measurements since each position was measured at 90 degrees).

Set the bore gauge at 66mm (2.5985") then went to work. All the measurement points were consistently between .0018" and .0024" below the standard. Oddly, measuring at the very top and very bottom of the cylinder (where the piston doesn't even swipe) and only found a couple points where the cylinder was nominal, most were still at .0010" below. Bottom line is all cylinders are showing about .0010" of out of round and taper, which is about 1/2 way to the service limit. Will measure the pistons next to determine if they are worn and to determine the piston to cylinder clearance.

[gmansyz]

Sounds like it needs some precision honing. To make round and remove the taper.
No Ball stuff.

[Nessism]

Sounds like it needs some precision honing. To make round and remove the taper.
No Ball stuff.

Always thought you bottle brush hone old cylinders. If the out of round and/or taper was bad enough you bored to the next size. In this case, the taper and out of round is within the service limit, so wasn't going to go down that road.

Going to measure the pistons tonight and then judge piston to wall clearance. If it's too large, that may force something different to happen.

[Wester Cooley]

If you are still under service limit. Find someone with a Sunnen hone and see if they can get rid of some of the egg and taper. Then rering that puppy and be done with it!!!

I would rather have a straight cylinder with a few more tenths of clearance than a egg shaped one that has been ball honed.

[Nessism]

Here are the numbers. With the clearance what it is, not sure taking away metal is the best approach.

P1010960 by nessism, on Flickr

Piston fit by nessism, on Flickr

[Nessism]

Not much to report. Going to do some more blasting today, and maybe some painting tomorrow.

Gathering parts together is keeping me busy. Bought a late model front master cylinder, but struggling to find a rebuildable core for the rear. All seem to have pitting in the bore.
This is one I got off ebay...which is going in the trash can.

P1010404 by nessism, on Flickr

P1010406 by nessism, on Flickr

[gmansyz]

Would a GS1100 master fit? Maybe a GSXR?
G

[rustybronco]

Going in the trash can AFTER the seller refunds your money?

Can't hurt to try.

[Nessism]

Going in the trash can AFTER the seller refunds your money?

Can't hurt to try.

Seller was cool. Refunded straight away. Finding a good unit is going to be a challange though. One guy on KZr Forum is sending me some photos. Fingers crossed.