Kawasaki Z500 B2 1980 refurb after 78260 miles

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linuxrob
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Mon Oct 14, 2019 5:28 pm

Decided to make a cylinder head stand, used wood as still have some bits of my old gate left.
Basically I wanted to have the head raised up from the bench and enough clearance to get the valves in and out plus valve spring compressor in without having to balance the thing on blocks. Seen a few on youtube like a "V" shape in metal but I made just a vertical stand. The wood is a bit thick, made a "H" shape using the head gasket as a template and also marked out the holes for the studs.
1 Wood blocks assembled and ready to mark out with head gasket as template.JPG
Have a dozen 8mm coach bolt 200mm long left in my bolt draw and using my drill press made 8 holes. 8.5mm wide. I used the center 4 holes and 4 outside holes of the head. Fitted the bolts with the head gasket keeping them aligned and tightened them down.
2 coach bolts fitted and alligned with gasket and tightened up.JPG
Ran 2 M8 nuts down each stud then 1 x M8 steel washer and 1 x M10 copper washer to approx the depth to give me a full nut sticking out the 4 outside head mounts. Copper washers of course to prevent any scoring of the Aluminium head, hand tight to stop any distortion.
3 head supported and full nut on with copper washer hand tight.JPG
4 head supported undeneath on copper washer 1 nut and 1 locking nut hand tight.JPG
5 head supported.JPG
even supports the head upside down for combustion chamber cleaning and valve lapping.
6 head supported upside down.JPG

Good result. Now to get on with some work.

Rob B
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Tue Nov 26, 2019 4:22 pm

Well finally got on with the jobs to do. Cylinder Head Clean and Blasting.

The easiest (costly) option was to send it with the cases barrel etc to Tiger blast nr York for vapour blasting but being a stubborn bugger and wanting to do as much as possible myself, besides the weather is rubbish and nothing on the telly.
01-head before paint-end.JPG
02-head before paint-exh.JPG
03-head before paint-intake.JPG
Before blasting the head was washed with small tooth brushes in diesel and then with scotchbrite in hot soapy water, after drying it off with the air line used 2 coats of paint stripper, then washed 2 more times and airline dried. The combustion chambers were blasted with soda and came up great. The remaining paint had to blasted with the fine black grit I got from the media suppliers in Newton Aycliffe. Had to be very careful not to go anywhere near the bearing surfaces but even plugging a lot of it up the blast media went everywhere.
08-Head blasted-end.JPG
09-Head blasted-exh.JPG
10-Head blasted-top.JPG
05-Half blasted-detail.JPG
After blasting and blowing out with the airline the whole head was washed in diesel then in hot soapy water. A further wash with my power washer was followed by hot clean water and a dry with the airline. It is also imperative the you re-oil the valve guides after each wash, they will flash rust.
11-head wash no 4 results.JPG
12-head wash in running water and bottle brushes.JPG

A further power wash and hot water rinse was carried out followed by 2 more brush washes and power wash until no more debris was left in the bottom of the bowl. It pays to keep washing and rinsing, the power washer set to a needle spray down the oil ways was great but I ended up very wet.
13-head wash no 6 results.JPG
15-filter after.JPG
14-head wash no 8 results.JPG
When it comes to my spare head, or any other for that matter I will plug and mask everything. The soda is no problem as it dissolves in water but this fine grit was a real pain to get out. I suppose a large hot ultrasonic tank would be a good idea but for me impractical and way over budget (see comment at the start of this post).

Painting next

Rob B
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Thu Jan 09, 2020 3:04 pm

Nov 27th update, better late than never

I got the heater on in the shed and used up the last of my Satin Black paint on the cylinder head. The masking and etch priming was done a few days ago so was ready to apply some colour.

Masked primed and bottom coated with Satin Black, this is an old can of Wilko's Satin Black enamel.

Below with a just a mist coat of black, old bolts and exhaust studs screwed in and old head gasket used.
16-head exh masked.JPG
17head intake maked.JPG
18-head underside masked.JPG
Mist coat dried followed by a medium wet coat and 2 wet coats. left to dry then turned over.
19-Head bottom done top to do.JPG
20-Head exh almost done.JPG
21-Head intake almost done.JPG
22-Head side almost done.JPG
This is where my can ran out. Will let is harden and have a close look at the finnish and decide if Wilko's Satin black is to used to finish off the head and then the barrel.

While we're here this is my shed as I was preparing for today's painting with the GS125 outside in the cold.
23-Garage away from paint booth.JPG
24-Garage towards paint booth.JPG
Finally, yours truly in suitable attire.
25-Paint booth.JPG
Rob B
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by Richzx6r » Thu Jan 09, 2020 4:06 pm

So its coming along slowly then :) good to see you are taking the time and doing a proper job on it :thumb:
Its better when its loaded

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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Fri Jan 10, 2020 6:00 pm

Richzx6r wrote:
Thu Jan 09, 2020 4:06 pm
So its coming along slowly then :) good to see you are taking the time and doing a proper job on it :thumb:
Cheers, will post more v soon
Rob

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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Sun Jan 19, 2020 4:49 pm

After a good Christmas break it's back to the shed.

Left the lacquer to harden before final check, clean and rebuild.
head ready to assemble top view.JPG
head ready to assemble.JPG
Very pleased with the job so far, this my spare head with valve guides just in spec. Got the number of a local guy to make up some Phosphor Bronze guides for the original head.

No 2 Combustion chamber before
No 2 Combustion chamber.JPG
No 2 Combustion chamber after
No2 combustion chamber.JPG
You can see that soda blasting makes short work of getting rid of the carbon deposits.

Valves lightly ground in, fitted with springs just compressed then tested with water in the inlet and exhaust and air line blown around the valve face, no bubbles, lovely.

At this point I checked the seals and gasket box and I had not ordered any Valve stem seals. MPS (https://www.motorcyclespareparts.eu/en) had a 10% offer so ordered the seals, 2 engine bolts and some rear sprocket tab washers (the Z500 rear sprocket is held on with 4 bolts not 6 as with the 550).

So while I wait will have to find another job to get on with

In the meantime here is the measurements relating to the valves.
valve clearence.jpg
You can see the valve heights are all well within spec, should hope so as they have only ever had a light grind in.
The only thing to look at is the No 3 Exh valve and No 1 and 4 Inlet clearance, will look through my shim collection to get them in the middle of the recommended settings.

Till next time...
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Sun Jan 19, 2020 8:03 pm

Valves ready for installation.
01 valve gear all cleaned.JPG
More time in the shed this week. Seals arrived in a few days, nice quick post from Europe.


Here you can see the difference between OEM seals and pattern ones. The Kawasaki part number is: 92049-1153 which replaced the earlier part number 92049-1050 both these seals have the following dimensions 5.5 X 12 X 6 X 9.8mm. The pattern seals have a hole for the valve at 6.0mm, so oversize. The old seals are from a pattern gasket set I bought 4 years ago, a Vesrah one but still the seals are not correct. Always use OEM seals and head gaskets.
02 vlave seals oem vs patern.JPG
After a good whizz round with a alcohol soaked rag the head was placed on the stand and the new seals greased with Red Rubber Grease.
03 apply red rubber grease to new seal.JPG
Located with the paint brush (non brush end obviously).
04 using paint brush to align new seal.JPG
and pushed on
05 push on new seal.JPG
Valve oiled and inserted from below.
06 push in valve from below.JPG
Springs, top retainer in, springs compressed and collets fitted.
07 valve spring compressed collets in.JPG
Before unscrewing the spring compressor I find it a good idea to place some cloth over the collets to stop them pinging out.
08 valve spring compressed collets in and paper in to stop collets spring out.JPG
The other 7 valves were fitted in the same way.
09 all done.JPG
Head was now covered in bubble wrap and stored out of the way. The Exhaust studs and inlet boots will be done last to avoid damage (to me if not them)

Exhaust studs are with the rest of the bolts in the to zinc plating que.

Pistons off next
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by fastbob » Sun Jan 19, 2020 8:48 pm

This becoming a restoration masterclass .

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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Sun Jan 19, 2020 9:23 pm

Cheers Bob, this is the first time i have been able to fully document a full strip and rebuild. I have had many a bike in bits over the last 40 odd years and it is good to record all the jobs. Did a small thread on my Bandit 53000 mile tidy up a few years back, will repost it here I think.

Rob B

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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by Richzx6r » Sun Jan 19, 2020 9:55 pm

Seeing all this I'm tempted to strip my old ninja and give it a good refresh not sure I'd be able to document it as well as you are though
Its better when its loaded

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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Thu Feb 20, 2020 3:47 pm

Barrels next

First job was to make sure my micrometer as reading OK, so out with the std 50mm bar and:-
03-Checking micrometer.JPG
03a-Detail Checking micrometer.JPG
Perfect
barel and piston measurement places.jpg
From Fig H49 in the manual (see above) Measurement are taken in 3 places, Top (10mm down bore), Middle (40mm down bore) and Bottom (10mm in from base of bore, unworn part). Both front to back and side to side measurements are taken at the above places to check for an oval bore.
04-Bore Measurement side to side bottom.JPG
05-Bore Measurement front to back bottom.JPG
06-Bore Measurement No 4 cylinder side to side bottom.JPG
07-No 2 cylinder bore - the worst one.JPG

Above is No 2 cylinder bore marks, the worst bore and No 4 side to side bottom measurement showing 55.01mm.
bore measures.jpg
Then i mic'd the pistons and gudgeon pins
piston measures.jpg
After making sure that the pistons – rings and bores were within spec and round enough it was time to prep for painting. I decided to just use soda blasting to clean the flaking paint and oxide build up as :-

A: The more aggressive media took an age to clean out of the head.
B: I did not want to accidentally blast he cylinder bore surfaces.

It took about 2 hours to get enough of the paint off to have a good keyed surface.

A good wash in hot soapy water, final clean hot water rinse and blow dry with the airline was followed by a smear of thick gear oil on the bores to prevent flash rusting.
06-Barrel after deep clean front.JPG
Painting next
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Fri May 01, 2020 3:42 pm

painting now done and quite a lot of things done as nowhere to go.
barrel painted done.JPG
Also used my cheap draper honing stones to deglaze
Deglazed.JPG
Soda blasted the pistons
04 All pistons done.JPG
03 No1 Piston under side soda blasted.JPG
rings fitted
Oil ring fitting correct.JPG
dressed up all my good old cross head bolts finished plating them and added them to the finished bottom end
100_4968-small.JPG
100_4969-small.JPG
loving this good weather.

Rob B
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Tue May 05, 2020 10:50 am

Kawasaki have there own tool to keep the pistons supported and level while fitting the barrels. Basically bent wire that fits under the piston skirt.
Piston bases OEM.JPG
In the past with the aid of my dad, fitting pistons 2 – 3 then 1 – 4 was made easier by stuffing more lint free rags into the crankcase holes as a support. Always had 100% success. Now Dad no longer with us I have need the pistons firmly supported.

My first Idea was to copy the Kawasaki tools but have not got the right gauge wire, so in the absence of aluminium plate or even suitable chunks of plastic to make a tuning fork shaped support I opted for plain kitchen sponges under the pistons. This was OK but in crease the stability I cut some 2 strips of hardboard to to lay over the mouth of the crankcase then wedge sponge round the pistons.
Piston base for refitting-labled.JPG
When the new oil seals turn up Barrels on

Rob b
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Sat May 16, 2020 11:53 am

Waiting for new oil seals for the barrel so took the back end apart again and replating the bolts this time with the proprietary chemicals and making them really shiny.

So far done the disc bolts and sprocket nuts and bolts and half the spindles. Also did the nuts for the inner tube / tyre securing bolts.

here is the wheel bits bolted back on
rear wheel black sprocket nuts done 2020.JPG
rear wheel black disc nolts done 2020.JPG
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Re: Kawasaki Z500 B2 1980 refurb after 78260 miles

Post by linuxrob » Sun Jun 21, 2020 9:03 am

Finally my oil seals arrived:

Anyone with a Z550 or GPZ or maybe any Z from this era and possibly onward when you are cleaning the crankcases, blasting or otherwise, make sure you check the part list diagrams for small "o"rings if a couple of your head stubs are NOT blind drilled and tapped holes.

On the Z500/550 series there are 2 studs drilled and tapped through into the upper crankcase. They have each a small 8mm "O" Ring fitted, they No 3 on the part diagram. Part No 670D1508. not to be confused with the 2 oil redistrictor "O" Rings for the barrel No 10, part No 92055 - 101 now replaced by part No 670D2010
upper crakcase dtud o rings no 3 on diagram.jpg
upper crankcase stud o ring overview lables.JPG
upper crankcase underside stub detail.JPG
this was the state of mine
rear o ring OK.JPG
The rear on was OK
front o ring split.JPG
The front was split so I ordered and replaced both.

I nearly forgot to fit these little buggers before the new base, Phew!!

using my sponges as Piston supports the old pistons and rings went in with the minimum of fuss.
piston supports ftted.JPG
piston supports ftted-3 and 4 in.JPG
refitted.JPG
Final job for the day was new "O" Rings later oil restrictors and head back on
Barrell and head fitted.JPG
Barrell and head fitted-2.JPG
All bolts torqued up. Tea Time.

Rob B
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