Kawasaki Z550

Much work has already been done to strip down this rather weary looking example of a Kawasaki 550 but if memory serves me correctly it was heard to be running earlier in the year, before the strip down began in earnest. Because the frame is in very poor condition and bits have been cut off it, a replacement frame has been purchased for it that now awaits powder coating.

Today the serious work of removing the engine from the old frame began.  Jon, Jack and Cory took the biggest role in this but were frustrated by corroded engine bolts. Most notably the two lower front engine mounting bolts.  Although each bolt is quite short its location and that of the nut securing it, leave it exposed to spray from the front wheel.  At some point in the past someone had clearly had similar issues because the aluminium fin in front of the right hand bolt/nut was broken.  With careful use of mole grips to twist the head of the bolt back and forth and a liberal spray of GT85, the offside bolt was eventually persuaded to come out of its hole.  However there was no such luck with bolt on the nearside that eventually rounded off beyond the point of redemption.  Whilst it might be possible to angle grind the head of the bolt off, the safest option would be to drill into the head in stages until the drill size matches the diameter of the bolt and the head parts company with it. There is then the small problem of removing the remains of the bolt from the crankcase without causing further damage to them.  However once the crankcases can be secured on a bench or even tipped on their side, it will be much easier to use a hammer and drift to start the process of breaking the rust’s hold on the bolt.