During my 1st engine rebuild on my 7, I noted that the stock grade bolts stretch way too much. Therefore went to grade 8 or better on the bolts. That moly lube and antiseize are good items to have in your tool box.

 

That's interesting, Which bolts did you find stretched the most. How did you know? I know that it is intended that the threads deform at least a little bit to keep the tension in the bolts. I agree that swapping out the bolts is a good idea. how did you find all the bolts you needed? Thanks for the tip

In other news, I was working on a KZ750 motor on the timing cover. I was able to drill out the bolt that was snapped off in there. I was just about done tapping the hole...SNAP! broke the tap off in the block. pissed. I am trying to use JB weld to join the tap back together, I am hoping that it will give me enough to back out the tap enough to get a vice grips or somthing around it. We'll see.

 

Well I got a little somewhere tonight...I put the motor with the good tranny in the bike to try and get off the sprocket nut, it was much easier than I thought it was going to be. So I thought while i had the motor in i would try and fit some of the major components on the bike. I had to try a couple times to put the all the coolers and the front motor bracket in. it looks like the two back motor mounts should be put in first, connect the oil cooler hoses, put on the headers then slide the radiator up and fasten the top two bolts and slide up the lower fairing bracket with the oil cooler already mounted. Fasten the motor mounts and frame mounts. pictures should be below...enjoy.



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I was able to find all the bolts for the pegs...happy about that. Back to the grind this week, I might get a little time to tinker during the week.

Cheers


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Well, it's only tuesday and I am freezing my ( l )'s off...well it's Maryland, I can't complain...I could be in Chicago.

I am doing a little poking around today on the motors....

I found two gigantic bolts with seemingly no place to go right under the head stock. I checked the stock A-1 motor and the Head on the motor I am pulling the tranny out of has a different casting. It seems like for the A1 ninja motors and frames that the designers thought they needed the upper motor mount on the head and later decided they didn't need it on the A-3. however the good news is that the rear and lower front mounting bolts (lower fairing/oil cooler/ radiator) bracket

I would think that having the frame mount on the head would be a good idea unless the frame torques so much that it put un needed stress on the motor, but it is supposed to be a stressed member right? Can anyone confirm any of my su****ions?

Looking a little further into the differences, I found that the intake runners for the carbs (A-3) are angled downward at about 30 from horizontal vs the runners on the A1 which are just about Horizontal. It makes sense for the designers to change this, air doesn't like to turn corners.

So some notes:
1. There are some big differences between the A-1 and A-3 motors (If there weren't, we would be wondering if Kaw eng's where doing their jobs.

Comments and questions are always welcome.

 

hey 1984zx900. I just wanted to say good luckwith your project. I remember when I was a little younger, I started a project on a 1980's Honda cruiser bike withmy dad.It was our first time and we disassembled the bike, unfroze the engine, changed the cyclindersand a few other things and then when we finally put the bike back together it did notstart at all. I supposeif we stuck with it a little longer wewould have eventually got it to work, but sadly wesold it because we did not have the luxury of time to work on it.So I just wanted to wish you the best of luck with your bike and no matter how tough it may seem, stick it out because I'm sure it will be very rewarding.

 

Thanks for the encouragment, it does get frustrating picking up someone elses mess. This bike is by no means obsolete, so i know that it will be worth while.

 

Why you should check the weather in the morning before you ride to work!!! No one can say that I'm not Hard core!

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you da man 1984zx900[sm=hail.gif]does the heated seat and handgrips help still????

 

Nothing heated on there yet...Sorry man. Alot of wet (I) though. I am looking into the heated grips and tulsa hot foot. I think I need to put it away until it warms up to above freezing...Black ice in a car is scary, black ice on a bike is a tradgedy.

I guess the A1 will get a little more attention now...

Cheers