Kawasaki Sportsbike Riders Club - Australia - Online Forum

Thanks to paul (sninynoggin) we have completely disassembled my engine!

now the problems it had... all it was, the primary chain hitting the engine... theres a nice 45* grind on the cover but it will be fine. and the cam chain was a bit loose too so those 2 will be replaced, piston rings will be replaced, all the gaskets, clutch was fine, shaft was fine, gear dogs were in excellent condition for its age dont know what could be wrong with the stud hold the #4 header, forgot to ask paul ... a lot of shit was in the engine to a new K&N air filter will have to be bought, and gotta redo the forks... air leaking from them so gonna send them to TJ's see if they can redo them and this project should be complete within the next 3 months! (i hope)

Here are some pics... ill take more when theres sunlight!!

Heres are some more pics of the main parts... have a look at one pic in particular and see what the primary chain was doing to the engine











HAVE A LOOK HERE AND SEE WHAT THE CHAIN DID TO THE ENGINE... it grinded about 45 degrees off the cover....

wowsers, took a little while to figure out how that all went together but fmd that's a decent bit of damage. I take it that there's no way for that chain to have its tension kept snug then?

the chain was at max tension apparently... time 4 a new one

Damn my primary chain is loose as and has one inch of freeplay... I think that you have discovered the patented Kawasaki primary chain tensioner- the engine casing! The engine doesn't have a tensioner for the primary chain. My Kawasaki guru reckons he has never seen a primary chain snap but I might be the first one because I tow another bike behind mine. If you look at the picture with the hand in it, there is a bearing behind a cap with two screws in it- in all three of my engines the outer race of this spins in the engine cases- I think it is the starter shaft? I think the primary chain is connected to this shaft too. I wonder what yours does? I should do this sort of rebuild to mine. Gave it a 1mm overbore recently but left the bottom end.

I feel sorry for the table, its gunna be a biatch getting the oil stains out

What's also got me buggered is how you got the engine out without removing the rear wheel, shocks and swingarm? I had to resort to all sorts of bodgyness to swap engines. I ended up laying the bike on its side and lowering the engine into it sideways with a block and tackle. It's a tight fit in there!

nearly all those little Zeddie motors with the primary drive chain have a lot of free-play in the primary chain......don't expect a new chain to have much less tension than the one you just pulled out.....I just had a look at the service manual for the z650. The service limit on primary chain slack is 27mm......it is recommended that the chain be replaced if it has worn to 1.4% longer than stock. The length of a new chain is not specified...

Bones - as far as I know, the bottom-end in all these donks (GT750, Z750, Z650 etc) is basically the same, with the obvious exception only being the output shaft and pinion on the GT7fiddy.......all the other internals are interchangeable between models ? ( there may be slight differences in the actual gearingon the input/output shafts in a couple of the gears though..) ? There are big differences with the frames and running gear though...

Good luck with the rebuild Panza - the GT750 was voted Two Wheels "Bike Of The Year" back in 1985 or thereabouts....

stop posting pics of parts and farkn start cleaning

bonester you didnt have the help of Paul lol... we didnt have a manual... we just took it apart

First we took off the shaft drive bolts then the drive...just pulled it out with the shaft!...then we pulled out the engine...but we had to jack it up a bit to move it out.

Dammit! The manual says to pull the entire rear end.... I guess I saved buying one gasket though. (shaft box on side of engine)

Mate how is it progressing? Got a lot of work ahead of you there!

I cleaned out all the oil and grease i could out of that farking engine... it took me 4 days to finish it all... ive never seen someone so dirty in all my life LOL!!

I also need to buy 2nd hand front forks... gonna set me back $150 for a pair of GT750 forks... excellent cond, got a strong recoil on em. Also got rid of the stupid air system it had on it...
(sorry bonester if this hurts ur feelings lol if you want you can buy the bike )

Ive ordered the Primary chain and the Timing chain from K Sydney City Motorcycles... was cheaper than other places i asked... in total it was $250 for both chains from Japan, so in 3 weeks time ill be calling upon my Master and Mentor Shiny to help me put it together and test ride it for me!

Also if anyone else wants to come help put it back together ill throw together a BBQ...
Once all the parts come in ill take some pics and let you all know when its done

and i might test it at the track

Got spare forks you could have cheaper than that!

oh really? How much? what condition?