Kawasaki Z550
Today Jack, Mark and John removed the remainder of the ancillary parts from the original frame ready to add them to the new frame. Whilst the back brake shoes are in a reasonable condition, the spindle that twists to open them was not. Firstly it had corroded into the brake plate. Secondly some clever soul had modified it by drilling between the spindle and the brake arm to accommodate a nail! This is a good old fashion bodge for those occasions when the splines on the spindle or the arm are so worn, that there is a danger of the arm spinning on the spindle when you stamp on the brake in anger. The arm, spindle and the O-ring (Designed to keep water out from around the spindle) all need to be replaced. After much debate – shall we, shan’t we, shall we, shan’t we , we have ended up with a ‘Shall’ we as far as having the new frame and the wheels powder coated. This meant that things like the swing arm bushes and wheel bearings had to be removed. One of the circlips securing one of the front wheel bearings was bent by a previous mechanic and needs to be replaced.
Phil the ace club mechanic had bought along his pressure washer and by a stroke of luck I found a suitable water supply. Then in the absence of a sack barrow Jack and I manfully carried the engine outside and I gunked it and pressure washed it. It is still not a thing of great beauty but at least it is less grimey. A further problem that was overcome was that the ignition’s advance and retard unit was seized. So although the would run it, the ignition wouldn’t have advanced at higher revs and the engine would have been gutless. However a generous spray of GT85 and some careful prying eventually had the unit working. It should really be taken apart and greased but that involves removing some tiny e-clips and I am still building up towards that!
All the cam cover bolts came out ok, all 26 of them. The cam cover came off easily. It revealed a pair of cam shafts that appear to be in good condition.
In order to decide to how to proceed with the engine I think the head and barrels need to come off. The prospect of removing the cylinder barrels fills me with dread. There are ten or twelve studs securing the cylinder head and barrels to the engine and each one is open to the elements where it passes through the cylinder block. Having seen how well rusted the engine bolts were, I can only hope for a miracle where we find that corrosion hasn’t welded the cylinder barrel to the studs!
Finally I hope there valves do not require adjustment because Mr Kawasaki decided in his infinite wisdom to make them of the bucket and shim design and to place the shims under the buckets! This means that there is little chance of the shims flying out but the cam shafts have to be removed to change the shims.