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1981 Kawasaki KZ750 Resurrection

Not a whole lot of progress to report. Need to get off my butt and get the valves over to the machinest with the centerless grinder so the head can be reassembled.

Sold the cylinder head off the spare engine. Some kid on KZrider.com was in need so I cut him a good deal. Guy gets the head and low and behold, two of the valve seats have chunks missing. Bummer. I've never seen such carnage on a GS. Needless to say I refunded him. Out shipping $ too. Learned a lesson; don't sell used engine parts without checking them out first.
 
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Been on an exhaust system buying spree. First I bought a NOS Supertrapp header. Haven't found an appropriate muffler yet though. While searching I came across this stock ZR-7 stainless steel exhaust. Got a killer deal so couldn't pass it up. This one is close to a straight bolt on, but knowing how things go I'm expecting some sort of hiccup.

P1020455 by nessism, on Flickr

ZR-7 Pipe by nessism, on Flickr
 
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SVSooke said:
Not to add fuel to your exhaust spree but did you see these http://www.z1enterprises.com/ItemDe...(80-81)+4-1+S/S+Exhaust+System&item=DECOM2767 ?:topsy_turvy:I suspect you have;)
Click to expand...

Yes, saw those. In fact I started a thread here about them a while back. It's good to have options.

My first choice would be a nice clean set of stock KZ750E pipes. Second option would be a nice Supertrapp system - chrome, or better yet stainless steel, although I'm not even sure they made one. The ZX-7 system interests me because it's stainless and OEM Kawasaki quality. I may even try to graft the muffler onto the Supertrapp. Not sure yet.
 
OK that was you,wasn't sure.I'd LOVE to find a nice OEM for the GPz to but it would be expensive to buy and ship.From experience on my 85 750 I know how nice they are,also how lucky it was to have a full system.The SS Supertrapps are rare,I'm not sure about chrome ones.For me the best option at the moment seems to be a Delkevic.
 
SVSooke said:
SWEET!!!Hope you get and glad I linked:cool:
Click to expand...

Got it! Thanks for the link. I've got a saved search for Supertrapp mufflers but hadn't ran it in a few days.

Hopefully the hanger will align on my bike. Should be close at least.
 
Shouldn't be to far off,the KZ750 V&H on the GPz needed a socket spacer to the inside of the hanger.You might get lucky with the mid pipe giving some flexibility.
 
The ZR-7 exhaust came today and it's in outstanding condition. Dude that packed it didn't have a clue but it came through okay regardless. The exhaust is a TANK compared to the aftermarket Supertrapp. Heavy and sturdy. Once the engine is all put together I'll have to see how it fits up. Not a fan of the shields over the collector but that can be remedied easily enough.
 
The Supertrapp muffler showed up. Nice piece. There isn't any fiberglass packing on this thing (I think). Guess the discs that bolt on to the end of the muffler provide the full muffling effect? The aluminum muffler cover piece has some corrosion. Apparently "NOS" doesn't mean new condition. The ebay seller is giving me a kickback though so guess it's okay.

Supertrapp = 12.5 lbs
ZR-7 system = 29 lbs
KZ750E system = 25.5 lbs
 
Finally got over to the machine shop and had the valves cleaned up. Shop is called Costa Mesa R&D. The owner is awesome and has lots of nifty videos on You Tube. He did them on the spot and charged me $20. He had to cut them more than I thought they would need, and a lot more than those from my GS1000 that had more mileage. They are good to go now though so I'm gonna get the head assembled this weekend.

 
Got the valves installed this weekend. Lapped them first and gave the head one last wash down before assembly.

This head uses shims under the buckets, which are more work compared to the Suzuki GS's with shims above bucket. I had to assemble each valve into the head, lay the camshaft on top, check clearance and figure out what shims are needed. Then pull the valve back out and move to the next. I did this using only the inner valve spring to save hassle. After getting a full shim inventory the head was assembled properly using both valve springs, shims and buckets.

All but one valve was within a tight range of shim sizes. The one valve was off by a couple sizes. I think this valve could use a smig more ground off the stem but not sure it's worth messing with at this point.

The shimming process was made significantly easier because Mr. Koolaid Kid (George) sent me a care package full of Kawasaki shims. Special shout out to this wonderful generosity. Yet another example of how great the GSR is. Gotta love it.:D
 
Baby (small) update...

Kawasaki's of the KZ era have an air injection system to reduce emissions. Pretty good system all and all, but adds quite a bit of clutter.

The air ports in the head were taped 1/8" BPT and plugs added. Had a hard time finding some suitable plugs. The first ones were too small and the second set were a little too tight. Wound up using the second set and dressing them down a little with a dremel. They are in their permanently now. No turning back.

Valve cover with the reed valves and tubes is the original, and the nice clean one is what I'm using instead.

P1020559 by nessism, on Flickr

P1020558 by nessism, on Flickr

P1020561 by nessism, on Flickr
 
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Rebuilding the clutch hub this weekend, along with cleaning the engine cases one last time before engine assembly.

Some guy on the KZ650 site sells these nifty neoprene clutch hub bumper thingies that really tighten up the clutch action. With the stock bumpers the clutch had quite a bit of play, but none with the new bumpers. Just gotta find someone to weld this thing up now.

P1020564 by nessism, on Flickr

P1020568 by nessism, on Flickr

P1020565 by nessism, on Flickr

P1020566 by nessism, on Flickr

P1020571 by nessism, on Flickr

P1020572 by nessism, on Flickr
 
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What is the purpose for the three dark colored buttons and springs?
 
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