Motor Strip

Sunday was mainly spent stripping the final components off the cases

 Noting that there is a break in the windings of the stator - pretty sure that it's as it should be though

 Cleaning off more blue goo.

 Drilling out and re-tapping seized and sheared casing studs.

 Loads of heat

 Re-tap to make sure.

 Not really sure if I need to take the studs out or not - they seem pretty good - took this pic for reference given there are three different lengths.

 Another sheared casing stud - rare for me to use an easy-out and actually have it work easily!

 Some signs of a previous case repair - Nothing too drastic and can be forgiven seeing the bike is 40 years old.

Motor Strip

Managed a few hours tonight - hopefully get the cases apart and get a good look at what's going on.  Obviously someone has been in the motor but judging from the gaskets and goo used I don't think that they got beyond taking the head and barrels off. 

 Flipped the motor and removed the oil filter housing and then the sump.

 Pretty telling in here - loads of metal flakes and more gasket goo on the strainer.

Just spotted this lil' beauty as well  - a trip to the Tig guy is on the cards

 Sump pan was filthy with goo and tar.

 Multi coloured gasket and alloy heaven

 Worryingly - I could see a crank cap bolt missing.  Nothing like that in the motor so I guessing that one was removed from the sump aperture ?? Strange.

 Another sheared cranked case bolt. Shouldn't be too much of a problem.

 Cases apart - crank out - nice and easy - just had to clean up the threads on the jack bolt points.

 Just a reminder to me of another sheared bolt. This time it's a starter motor bolt.

 These marks could be when the cam guide let go

 Close ups of the marks

 That'll do for tonight - next will be stud removal and get the cracked casing welded.

Z1000A1

S'funny how things have a habit of coming about - Long story short I visited a customers house some 15years or so ago and dissolving in his back garden was a BMW R80 and a bigass furred up Z. My customer was about to leave the County and start a new life,  I was living in a small Cornish Cottage and just did not have the room for either of them. Fast forward 12 years and I had self built a large garage with a nice detached house (priorities)! Somehow  I had also acquired a stripped down Hodna Monkey bike (don't ask) which apparently some poor souls pass off as an interesting motorcycling metal. 

My old customer had also found his way back into the County and when we caught up I asked him about his old bikes. 

The BMW he had built into a very nice bespoke KATHY RAZER. No seriously! The Z he had passed on to a current work-mate of his who had stripped it from this -

[img]https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRZ1GoqRPLHoO4nK1ODzM0eWEx1EVJi1Hfc6cMapPlqj1Yw5fRh2WhTgtoKDPXdAh5aUY4UOl5zDmSttJxnaKO3bTJWHuYv6-FVjckjRe_v3wtWK2yc2B661fe380pcmMd_RbNeezK9E_8/s320/IMG_1887.JP[/img]  only significantly more corroded, to this -

[img]https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-j2-xGyDSzyD4oSpZVAN0UfeS2qZAA35P28zuSFdRxjkLm9i6aljQFcW-AbPGtXKKKKInUjiF1RgFc_lXt9BR6_1tgWUyKWGL8vQ6eyHsYrtftB0ggN4suyBmx87PTMrfm497yAw9oI4y/s1600/thumb_IMG_0006_1024.jpg[/img]

Apparently the fellow who stripped the bike had left it under his bench and all but given up on it as he was now consumed by a new passion. Yep he was into Hodner Manky Boikes!! So like a rat up a drain I accepted his offer of swapping his Z for my childs beach toy and promptly packed it into my van and got it home.  [img]https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRYf2m2Ps3k60CzSbHjVmQH5OhbMF29mEm2HHYpcK8SQuw8Xn9WDI7s6JQBHZ2i0eNZCoOkV_847kvM0t56QiRHbn8BuLS9VLgYFrVaRKNUvVOx5VvRTx3lU_U0m0IpR7rE68BW6zkL_zX/s320/IMG_1882.JPG[/img]

Roll on another couple of years and having finely honed my motorcycle de-construction skills on a Harley Sportster and an old Yam XS850 I decided that it was time to address the bleeding hulk lurking in the shadows of my garage. I'm not scared - much!

First job was sorting the usable chrome, tin ware, zinc bracketry etc. along with the frame and assorted ironmongery for plating blasting and powder coating.

[img]https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4dLsLPXP5i0-xQbSVs-1__ANuq3oN-qQUxhsneQwxLxE3__BYrnoonc4gIlYkrprUEIgOHAu2YmwCGpaZOOEoJ3_MgRFLoSDAcocP1pctliD0kL_IQvGS3t17SEm8whasA-mAzNKkGp1M/s320/IMG_3959.JPG[/img]

Calipers (of which there were several sets were sorted for the best specimens and sent to Powerhouse for refurb.

[img]https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJfjgbmun7rEU6eJ4_9t36OGRiY-bdVnkr2sK_xrHzD-t6PYvSce1aE5gEVKJql0wJxDxCb5NtxGckovDFlTELqNKUHYNxE27IdxTMaMhjO5aoREl_wEh72s5xh3IlZb2ucPwSXcSuSy-Z/s320/IMG_3960.JPG[/img]

Assorted nuts bolts and brackets to Mikey for Zinc plating following recommendations from this club

[img]https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjVKiaPaJWY5LbVM9Y-kIU087iJLBuUukhU-6H7cabc70d1XcknWCKnzFy2Lk1LYJAMeuoMwblyP8seOE2MNKY5_nxR5LoE6b2-QQ6u3CKqHNae89chxRvOGsiGIhATIezujAi7jYZs4fkV/s320/IMG_3956.JPG[/img]

Switch gear was stripped, again several sets, and sorted with other alloy parts for vapour blasting, anodising and polishing. The wheels were stripped and the hubs relieved of there bearings again prior to vapour blasting. The spoke carrier on the rear hub was totally FUBAR'd due to terminal rot on the steel spoke carrier, so that went off to a local engineering shop to be heated and pressed off. The steel carrier will then be machined and heat pressed back - (so i'm told). The engineering shop will also black anodize my switch bodies and master cylinder bodies. 

The exhaust with the bike is a decent Harris 4-1 but as I wanted it to be as close to the original look as possible I have been speaking to Roy at OSMC with a view to making me a set of these in Stainless 

I filled the larger of my two tanks with a solution of phosphoric acid to convert any rust lurking in the corners after years of neglect and the result looked like a new tank inside. The tank and panels were then sent off to my spray guy who fits my bikes in between car resprays. No rush. 

That pretty much brought me up to Sunday when with a rush of blood and armed with this amazing Kawasaki training video poached from you tube I set about the motor. 

Z1000 Motor Strip

First step of my motor strip, not really sure whatI going to find and if I'm honest I feel pretty daunted by the job. I was going to get a local shop to dot he job but decided to get stuck in. Externally the motor looked rough as rats in terms of furred up alloy and grime but thankfully no obvious damage.  I had been spraying the nuts bolts and head studs pretty frequently as I have had issues with seized and corroded fasteners on my XS850. Another thing that I learnt was to spend some time with a stainless pick and clean out all the cross head screw and Allen head caps to enable the drivers get a good purchase.  

Cam cover off and at first site the cams look really good.

No obvious wear or scoring.

Plenty of gasket gak visible down the cam chain tunnel.

Cams removed and followers labelled. Everything bagged as I go.

White metal cam shells look pretty good on first inspection.

Head off to reveal more nasty liquid gasket and very oiled up pistons.

Bores looking reasonable though.

Worrying that someone had been here in the past with loads of liquid goo

First sign of internal damage was this broken cam chain slipper - this could be the  reason the bike was stripped - it wasn't going to make any friends down here on it's own.

Another set of pics from a different viewpoint - more for my own reference really.

The barrels came away without any drama and the pistons look pretty good.

no obvious signs of a previous rebore - perhaps when I clean them up. 

Alternator cover off - more Goo.