83' KZ400 Engine Block Repair.....

[Ace Rimmer]

HELLO!

First post on (or in I'm not sure which) this forum and well basically, I'm really hoping that there's something that I can do with this love of mine! It's a gifted 1983 KZ400E thats been half chopped and just needs the finishing touches applied. It's from a dear friend and the bike represents quite a sicknificint part of my life from back in the good ol days so it'll be fooking wicked to get the mini beast back on the road or at least close to mot ready!
SO FAR -
It's been dormant for about 7 years, Now i find some time on my hands out it comes and (Cilla black) surprise surprise its actually turning over! Good testings from the starter motor, everything works all the way to the coils so have just received new ones of them when
DEVASTATING NEWS
On the front right lower engine mount, upon the engine side there a whooping great crack that looks as though its either been over tightened or the bike has been dropped on this side in the past. It passes right the way through to the other side i'm pretty sure it'll fall off when I take he engine out.
I kinda feel that its far away enough from the block itself that it may be repairable? What are your thoughts? Am I mad to think this may be possible?
Failing a fix, what other engines could I mount into the frame of my potentially prestigious ride. An upgrade in power would be nice but we shall see what comes up!

Thanks

Greg.

[Riejufixing]

Are these both the same mounting, one from in front, one from underneath?

You'll have to get the thing out, but it looks weldable. You want an artiste with a high frequency set. I'd guess that the damage has occurred due to incorrect mounting bolts allowing the whole engine to chatter and vibrate in the frame.

[Easy-X]

Dab of JB Weld... no, maybe not!

Just to put it in perspective here's (I think I have the right bike) a better view:

https://livedoor.blogimg.jp/mccraft/imgs/7/1/71510a03.jpg

So lower offside mount?
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[Ace Rimmer]

Easy-X - Yep pretty sure thats the same - the lower offside mount - on the engine side not so much the frame welded mounting bracket but the casting on the block itself.

Riejufixing - yep the same mounting, from underneath in pic2Glad to hear it sound fixable, thanks for the tip with the high frequency set there. was thinking this also, I notice there are different nuts on the end of some of these engine mounting bolts so was thinking

Going to get it out now and clean/inspect all the other mounting points both bike and engine. FINGERS CROSSED EH!!

Nice one thanks for the hasty reply, this is all the push I required!

[Bhud]

EDIT: removed link to crankcase that wouldn't fit

[Riejufixing]

[Ace Rimmer]

[stinkwheel]

You sir, have your work cut out if that and the hatchet job that's been done on the frame are anything to go by.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Nobby the Bastard]

I'm with stinkwheel.

Look at how much money you are prepared to throw at this pile of shit and see if you can buy a 50cc scooter instead.
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trevor saxe-coburg-gotha:"Remember this simple rule - scooters are for men who like to feel the breeze on their huge, flapping cunt lips."
Triumph Sprint ST 1050

[Tdibs]

''finishing touches'' seems a bit optimistic mate...


Sorry to say, but if that was in my shed, I would be parting out what I could. You have a chopped to scrap frame, a engine with a broken mount, whats are the other parts like!?!

Such a shame as it seems like a original 400/4 kawa would bee a awesome little bike
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Previous : 09 Vanvan 125| 02' Sv650s || Current: 1999 Xj600n | 1992 DR650 RSE | 2005 Fazer 1000

[stinkwheel]

It's not unsaveable but it's going to take a lot of work. Considerably more than it's eventual monetary value. That doesn't mean it's not worth doing.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Pete.]

Could be that the bolt has rusted in the hole and the rust has burst the casing.

Anyway, it's a welding job to repair. Engine-out to do it even half right.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Riejufixing]

("but it's not profitable") See OP.

[Ace Rimmer]

Optimism is ripe at the moment! Yes quite a bit of work todo on the frame but with the engine out it should be a whole lot easier to work on + a well made placed heavy duty bracket somewhere on the subframe should do the trick. I'm open to suggestions on that one!

As for the monetary value I'm not so fussed as Im able to fabricate most of the brackets/mounts/farings myself so really as I know the engine is sound I'll not be giving up on it quite yet! (+ that metallic green finish on the tank is to die for!)[/quote]

[steve the grease]

Pete you got there whilst I was typing.
My opinion is that what you have is a corrosion based crack , water has got in between the bolt and has sat there , lots of that shitty white powder aluminium corrosion has been the result and that has expanded and cracked the boss.
I don't think its a big deal, the mount is under compression in that one face of the alloy boss sits against a plate of the engine mounting, as long as it's welded up and has the joint face between the engine and the frame reasonably flat and you can get a nut and bolt through I think it will be fine.

Lots more places are doing ally welding nowadays as the price of TIG gear has come down.

Go for it.

Anyone can buy a new bike , a bike that represents a ' significant part of your past' is unique to you.
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All the above is my personal opinion, you can see my lips move, but I'm talking out of my arse.
I've been riding, and fixing , bikes for 50 years, in that time the more I learn, the less I am absolutely sure of.....

[Ace Rimmer]

More bits....

[steve the grease]

Yeah , that is looking a bit sad, are those other pictures the exhaust ports?

A few cases on Ebay for 50.00 ish up. something will turn up.
____________________
All the above is my personal opinion, you can see my lips move, but I'm talking out of my arse.
I've been riding, and fixing , bikes for 50 years, in that time the more I learn, the less I am absolutely sure of.....

[Riejufixing]

Can we have one thread, as the two existing are so similar?

[Ace Rimmer]