kz900 rebuild

just picked up 76 kz900,i wAS told that it had 1000 cc cylinders on it ,stamp on lower end is 1015cc.it also has a cam wich is above stock,how do you tell the differance?.
shop manual said there strips on it 1,2,3 .what is stock?
also after pulling cylinders off , i saw a small button on each of the piston con rod ends.the shop manual does not show them,first 3 cyls they are on the left side and #4 is on the right side.
miced the cam journals all with in spec.
also have another eng that came with it with 903cc
cylinders on it.
should i keep the big cylinders on it or put the 903cc back on?
any help would be great thanks

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If the bike is running well as is (1015cc) why would you want to down grade to 903cc?

Or are you wanting to use the 1000 motor for a different project and keep a running bike...

As for the CAM, unknown...

OMR

no the bike is not running.i plan to do a complet rebuild on the eng and frame. just not sure if i want to go stock or keep what is in it.the eng crank has been welded,bigger cam.10.5 comp pistons , head ported and polished,rear swing arm extened 2" front end angled 1 1/2 * that is all i know about the bike so far

Does the cam have CWC cast in it anywhere?

The buttons sound like wrist pin buttons that are sometimes used instead od circlips to hold the pins in.

Are there circlips in the pistons holding the pins in?

Jay

hi jay no clips . i took pistons off the rods today.
saw slight were on the top and bottom .
any info on crank ? found 2 # ay az .
i was told that the crank was welded, can not see any weld on crank, am i looking in the wrong places ? all i can see is inbetween the rod and crank right now.

KZbasket, I sent you a PM on this as well...

Welded Rank:
Image 4 just above the outer bearing displays the weld. Basically it's for strengthening the crank. They would also balance the crank. It's mostly for high power bikes for racing and drag.

If for everyday style riding, Granted, nice to have if already done and done right but not necessary and it is pricey work.

aperaceparts.com/crankwork.html
www.faliconcranks.com/crank_svc.html

Since you only have a 1015cc, I wouldn't worry about it. As displayed, you need to split the cases to verify this, it's the only way...

file:///C:/Kawasaki%20KZ%20900/Engine%20Rebuild/okndrebuild.html

On the back left side (carb side of cylinder), lower end of the cylinder there is a stamped cc marking. KZ900's will be 903cc, KZ1000 will be I believe 1015cc. Seems your's is a 1015cc if I'm understanding your posting.

The Weisco 1015cc kits are drop ins for the KZ1000 cylinder. As for mine, it's 903cc bored and honed out for the 1015cc pistons. Anything larger would require new sleeves.

You will need the manuals to find out which head was placed on this bike. The PO either used the KZ900 head or swapped to the KZ1000 head. One way to find out is on the header exhaust studs, if 6mm then KZ900, if 8mm then KZ1000 head.

CAM:
The camshaft lobe lift can be measured using an outside micrometer.

Lift is determined by measuring the lobe from heel to nose, and subtracting the base circle measurement from it.

www.autozone.com/az/cds/en_us/0900823d/8.../repairInfoPages.htm

The lower end cases are pretty much the same unless it's a MKII version.

KZ1000/1100 Service Manual: Need WinRar to decompile
www.bad-pc-company.com/Kawasaki-KZ1100-Service-Manual.rar


Hope this helps,

OMR
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