I am tweaked!!!

zeerex99

zeerex99

New Member
I'm rebuilding a 78 KZ10000 A2. I bought a NOS head including the cam bearing covers. The old head was shot. Started installing the cam bearing covers last night. Spec is only 13.5 ft/lbs. Five of them snapped off way before I hit the spec. Now I'm down to a long weekend of CR6, a drill and an EZ out. Is it possible for NOS bolts to be degraded this bad??? They're aluminum and 32 years old. F*** me! Never had this happen before.
 
DEEKAYPEE8569

DEEKAYPEE8569

Well-Known Member
zeerex99 said:
I'm rebuilding a 78 KZ10000 A2. I bought a NOS head including the cam bearing covers. The old head was shot. Started installing the cam bearing covers last night. Spec is only 13.5 ft/lbs. Five of them snapped off way before I hit the spec. Now I'm down to a long weekend of CR6, a drill and an EZ out. Is it possible for NOS bolts to be degraded this bad??? They're aluminum and 32 years old. F*** me! Never had this happen before.
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If I understand what you're saying; you re-used the 32-yr old bolts? Steel, Moly or aluminum; makes no difference in MY mind; if you're installing new parts; use new fasteners/bolts, etc.. Maybe that's just me.....

Usual procedure for that kinda work is to replace the bolts also.....isn't it? :confused:

I could also NEVER understand why it's necessary to torque aluminum components.....like aluminum wheels on a car.....just don't make sense.

You're not "tweaked." You're "torqued.".....had to.....sorry.....
 
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zeerex99

zeerex99

New Member
What I did was find and buy a fresh new old stock head, still in the box packed in cosmolene. Now, perhaps it was a mistake to assume the bolts were bad (included with the head) but if the head is good, and looking new, why should the bolts be different. They look brand new but are snapping off. I may try using the old bolts. Looking for experience on this kind of situation. My life and career have been centered around working on engines and Navy propulsion machinery. This just seems to be a fluke. Thoughts/experience???
 
zeerex99

zeerex99

New Member
DEEKAYPEE8569 said:
You're not "tweaked." You're "torqued.".....had to.....sorry.....
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Been doing this long enough to know the difference between tweaked and tourqed. I've done both and been fine on both ends. All I'm saying is I'm dealing with something new. Could old bolts in a shipment be bad. Aparrrently the answer is yes. I'm going to work 0n getting the snapped off ones out and buying new ones. I've just never encountered this in 44 years. Just saying!
 
Dukesdad

Dukesdad

Well-Known Member
zeerex99 said:
I'm rebuilding a 78 KZ10000 A2. I bought a NOS head including the cam bearing covers. The old head was shot. Started installing the cam bearing covers last night. Spec is only 13.5 ft/lbs. Five of them snapped off way before I hit the spec. Now I'm down to a long weekend of CR6, a drill and an EZ out. Is it possible for NOS bolts to be degraded this bad??? They're aluminum and 32 years old. F*** me! Never had this happen before.
Click to expand...

sometimes a left handed drill bit will back them out. Are you sure about the 13.5? I have an '81 yamaha xs1100 and the torque setting for the cam bearings is only 7.2 ft/lbs. like yours, its an aluminum head...

This is cut from a kz forum.
KZrider.com - New cam bushings and cam chain -
They are called "cam bearing caps". You might want to give the PO a little brake. This is a common problem and it is Kawasaki's fault. They have the wrong torque listed in the service manual. many of us have stripped the cap threads in the head. Installing "quick-serts" or "Helicoils" has been covered many-many times on this web sight. so don't feel bad, you are not the only one in this boat. Yes, I have done it also. In the book it states that the torque should be 12 lb/ft when in fact it should be only be 105 oz/in.
 
Homer J

Homer J

Power Chord
zeerex99 said:
I'm rebuilding a 78 KZ10000 A2. I bought a NOS head including the cam bearing covers. The old head was shot. Started installing the cam bearing covers last night. Spec is only 13.5 ft/lbs. Five of them snapped off way before I hit the spec. Now I'm down to a long weekend of CR6, a drill and an EZ out. Is it possible for NOS bolts to be degraded this bad??? They're aluminum and 32 years old. F*** me! Never had this happen before.
Click to expand...

:yikes: Didn't know they made motorcycles that big. Anyway, good luck with your rebuild.
 
zeerex99

zeerex99

New Member
I got a hold of some people on KZ rider.com. Found out the spec listed in the manual is incorrect. It's nowhere near 13.5 ft/lbs. It's more like 6 ft/lbs. Most likely and in/lbs spec. Eh, I'll find out the real value and it gives me an excuse to buy another tool.
 
flomaster

flomaster

J.F. A sus ordenes!
Owned a KZ1000 MK II back in the day. I miss that bike. Traded it in on an FJ1200 and the guy who bought my old KZ uncorked the header at the dealer and got down the street from the dealer before hitting a car broadside. Sad ending.

Good luck with your ride.
 
zeerex99

zeerex99

New Member
Thanks for the info. The spec in the shop manual is way off. At least I didn't strip the threads. This is a never used NOS head and I'd be extremely p****d if the threads stripped out. This is the point where I slow down, use pentiful amounts of PB Blaster, drill carefully and break out the tiny EZ Out. Gonna be tight, the bolts are only 6mm.
 
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