I recently rebuilt the topend of my '82 KZ1000 LTD. I put new rings in, checked the valve clearances, replaced all the gaskets and o-rings etc.... Now that it is all back together though it smokes, a lot. About 5-10 seconds after it is started it starts to smoke. It's not too bad when sitting at idle. It smokes the most under acceleration, and engine braking. When cruising down the road it doesn't smoke at all (had a friend follow and watch and smell on his bike). It is bad enough that it fouls plugs quite often. I have had to put new plugs in #1, #2, and #3 and I only have around 180Km on the bike since rebuild.


Can anyone give me some insight into what is happening? Your help would be greatly appreciated.


Thanks for your time,
Scott

 

So the only hard parts you changed were the rings? Did it smoke before the ring slap? Did you bore/hone the cylinders? Did you check the valve guide clearances? Did you check cylinder out of roundess? Did you stagger the compression and oil rings?

 

The only hard parts I changed were the rings. I checked the valve clearances. Bored the cylinders. The cylinders are round, and I did stagger the rings as per the shop manual. Is it possible that I somehow damaged the valve seals when I had it all apart and cleaned it? It didn't smoke before the work either.

Thanks,
Scott

 

bored and at what cross hatch? Piston to wall clearance number? The correct ring material for the bore liner for correct bed in? End gap of the rings? Why take the head apart and possibly damage seals if all you did was a freshin up to the bore and piston. Some compression and leak down numbers are in order.

 

I'm sorry I made a mistake in my last post. I did not bore the cylinders, I just had them honed. The reason being was that 1 ring on both cylinders 2, and 3 were broken. My intention was only to check valve clearances and replace leaking gaskets. However when I noticed the broken rings I had the cylinders honed and replaced all the rings. There are some score marks in one of the cylinders but nothing terrible otherwise I would have bored the cylinders to rectify the issue. I measured the tolerances according to the service manuals and everything was within spec. when I reassembled it. I will get exact compression readings in the next day or so. What exactly do you mean by "leak down" and how do I measure it?

Thanks again,
Scott

 

http://autos.yahoo.com/maintain/repa...ques057_1.html leak down test....

 

OK... I will see what I can come up with. I don't have the guages for a leak down test but will see if I know anyone who does. I haven't gotten to the compression test yet as I worked 21 out of 24 hours yesterday and spent most of today recovering

Scott

 

After you did the ring slap, what kinda oil and what weight did you put back in her? How did you break in the new rings?