Post by mechtibs on Dec 9, 2017 23:42:38 GMT -5
Well this summer I decided to pick up yet another project bike (very dumb but I did it), after getting fed up with the 72 honda XL250 I was working on I was surfing the local classifieds and found a peach of a KZ550, complete bike minus the front axle for a $160. Figured I couldn't go wrong for that price, used a skidsteer to load it in the back of my truck and took her home.
Some of the problems found right at the get go was
1. The engine rotated only a few degrees before getting stuck
2. The ignition pickup and rotor were rusted solid
3. Rear brake was locked up
4. Carbs were gummed right up/stuck
I started with getting the rear brake unstuck so I could unload the bike, pulled everything apart found the cam that rotates to spread the shoes apart was heavily corroded, cleaned it up and the housing got it to work for now. Unloaded it then figured I'd tackle the carbs second so I could attempt a startup when I got the engine freed up.
2 weeks later the carb kits I ordered came in, took 4 hours to clean them up and swap out pats. Installing the carbs was a "royal pain in the you know what" with age hardened intake boots but I some how managed to get them in.
Ended up finding a brand new NOS ignition cam and mechanical advancer on Ebay in germany (part# 21148-1016) which I was able to snag for under $100 CAD blew my mind I got it for that cheap. Also at the same time I came across a complete 80 model KZ550 engine with carbs locally for $150 so I picked that up as a plan B if this engine didn't work out.
At this point with the remaining part I needed to get it running on the way I decided to tackle the engine problem, I figured the pistons were all moving as I could get about 35 degrees of rotation out of the crank which meant more then likely a valve was stuck open and contacting the piston...... good ol interference engine.
Popped the valve cover off loosed the timing chain and pulled the cams. Turned out I had 5 valves that were stuck open, little taping on them and they popped back into their seats. Another problem solved so I reassembled the top end and twiddled my thumbs waiting for parts to arrive.
Another week later the ignition parts arrived and it was time to attempt a start. Thankfully after I filled the carb bowls it fired right up first crank no choke. It was revving higher then it should have been just listening to it but it seemed to run good no ticks, knocks or oil leaks. So that was a plus, at the same time it also added more to the to do list. The tachometer wasn't working and it seemed to have electrical problems that need to be addressed.
That's as far as I made it before winter hit and not having a heated garage doesn't help. As of now I have $500 into the bike which is alright but it needs a hell of a lot more work. Still haven't decided what route I'm going with it. Trying to find photo's to give folks something more interesting to look at other then words.
Some of the problems found right at the get go was
1. The engine rotated only a few degrees before getting stuck
2. The ignition pickup and rotor were rusted solid
3. Rear brake was locked up
4. Carbs were gummed right up/stuck
I started with getting the rear brake unstuck so I could unload the bike, pulled everything apart found the cam that rotates to spread the shoes apart was heavily corroded, cleaned it up and the housing got it to work for now. Unloaded it then figured I'd tackle the carbs second so I could attempt a startup when I got the engine freed up.
2 weeks later the carb kits I ordered came in, took 4 hours to clean them up and swap out pats. Installing the carbs was a "royal pain in the you know what" with age hardened intake boots but I some how managed to get them in.
Ended up finding a brand new NOS ignition cam and mechanical advancer on Ebay in germany (part# 21148-1016) which I was able to snag for under $100 CAD blew my mind I got it for that cheap. Also at the same time I came across a complete 80 model KZ550 engine with carbs locally for $150 so I picked that up as a plan B if this engine didn't work out.
At this point with the remaining part I needed to get it running on the way I decided to tackle the engine problem, I figured the pistons were all moving as I could get about 35 degrees of rotation out of the crank which meant more then likely a valve was stuck open and contacting the piston...... good ol interference engine.
Popped the valve cover off loosed the timing chain and pulled the cams. Turned out I had 5 valves that were stuck open, little taping on them and they popped back into their seats. Another problem solved so I reassembled the top end and twiddled my thumbs waiting for parts to arrive.
Another week later the ignition parts arrived and it was time to attempt a start. Thankfully after I filled the carb bowls it fired right up first crank no choke. It was revving higher then it should have been just listening to it but it seemed to run good no ticks, knocks or oil leaks. So that was a plus, at the same time it also added more to the to do list. The tachometer wasn't working and it seemed to have electrical problems that need to be addressed.
That's as far as I made it before winter hit and not having a heated garage doesn't help. As of now I have $500 into the bike which is alright but it needs a hell of a lot more work. Still haven't decided what route I'm going with it. Trying to find photo's to give folks something more interesting to look at other then words.