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My newly acquired '77 kz900a5

Post pictures of your bikes without having to pull them to bits to qualify for Projects. Club eligible Z based bikes only please, anything else should be in the bottom shed.
Please use it wisely and be respectful of other peoples' pride and joy....
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Ultim8pc
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Joined: 5th Sep 2014
Location: Keighley, West yorkshire

#31 PostAuthor: Ultim8pc » Mon Dec 26, 2016 4:46 pm

Actually Tony Archer couldn't have been less interested if he tried..
Told me to buy a seat cover from Z Power and do it myself....

Ultim8pc
100Club
100Club
Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

#32 PostAuthor: Ultim8pc » Tue Jan 31, 2017 2:44 pm

Managed to source a decent conditon OEM RH sidepanel and badge to replace the aftermarket one which had no badge.
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Zedorset
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Location: Blandford, Dorset.

#33 PostAuthor: Zedorset » Tue Jan 31, 2017 3:11 pm

They are only original once. There must be a period seat out the somewhere!

Ultim8pc
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Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

#34 PostAuthor: Ultim8pc » Tue Jan 31, 2017 3:27 pm

Zedorset wrote:They are only original once. There must be a period seat out the somewhere!

True. I think I am going to get a new seat foam and recover the existing seat base.

Ultim8pc
100Club
100Club
Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

Re: My newly acquired '77 kz900a5

#35 PostAuthor: Ultim8pc » Thu Jun 15, 2017 8:42 pm

So, finally got some time to start work on the 900.
Started taking bits off the to clean up and I think it will tidy up well enough.
Did the valve clearances yesterday, a couple were well tight and had to go down three sizes to get them in tolerance. (eek!). Cams lobes look in good condition.
Checked the compression with the engine cold and got 85/95/90/85 psi. Will have to start her up and check warm but the cold readings look respectable I think.
I look at sorting the oil leaks next (tacho drive, alternator wire and gear change shaft).

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paul doran
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Re: My newly acquired '77 kz900a5

#36 PostAuthor: paul doran » Sun Jun 18, 2017 9:14 am

100 is the working range
You may have a few seized rings
Pour diesel or hot waste oil into bores and leave it for a few days
Then redo the compression test
way too many Zeds

Ultim8pc
100Club
100Club
Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

Re: My newly acquired '77 kz900a5

#37 PostAuthor: Ultim8pc » Tue Jun 20, 2017 11:01 pm

Re-did the tests with some oil in the bores and got
115/120/120/125

Ultim8pc
100Club
100Club
Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

Re: My newly acquired '77 kz900a5

#38 PostAuthor: Ultim8pc » Sat Jun 24, 2017 11:47 am

Stripped the carbs down to run them through the ultrasonic cleaner.
Again, other than the grot caused by leaky float bowl gaskets - they are in excellent condition with pretty much no wear.
Had a couple of screws that wouldn't come out without the use of the mole grips...
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Ultim8pc
100Club
100Club
Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

Re: My newly acquired '77 kz900a5

#39 PostAuthor: Ultim8pc » Tue Jul 18, 2017 6:04 am

Been a bit ill for the last few weeks, so not moved forward too much.
However, upon closer inspection the float needles are a tad work, so I have full refurb kits ready to fit.
Taken the sump off and it's all pretty clean with no crap in the oil pump gauze filter. Getting the old sump gasket off was a complete bastard as it was hard as rock..
Going to fit a new oil pump o-ring as the existing one is a bit hard. Also fitting a new seal and o-ring to the tacho drive.

Ultim8pc
100Club
100Club
Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

Re: My newly acquired '77 kz900a5

#40 PostAuthor: Ultim8pc » Sun Aug 06, 2017 9:14 pm

Finally well enough to get more work done.
Carbs all re-assembled, with float valves, o-rings and gaskets.
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I also removed the sump, cleaned it up and the front of the crankcases, fitted new oil pump and oil filter o-rings.
No debris in the sump (just some thick oily gunge) and no crap in the pump gauze.
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Ultim8pc
100Club
100Club
Posts: 308
Joined: 5th Sep 2014
Location: Keighley, West yorkshire

Re: My newly acquired '77 kz900a5

#41 PostAuthor: Ultim8pc » Thu Dec 14, 2017 4:04 pm

Been a bit busy with other stuff, but I have been doing some work as time permits:
Stripped out the wheels, forks and swing arm and cleaned everything up.
Bought a new battery and also managed to pick up a very nice condition Kerker to replace the tatty one that's currently fitted.
Need to buy a standard seat cover and I have discovered that the rear brake return spring is broken, so will need to get one.
Hoping to get it all reassembled by Christmas and then I can start on getting it registered!


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