78 Kz 650 sr ENGINE STUCK !??

Cadillac · 07-04-2009

What up first of all i am new... to the forums and the world of KZ's i picked up a Kz 650 sr from my friend for a 100$ but the engine is stuck i can not get it broke loose... the bike was a 1 owner but in 1997 dude got cancer and jus drained the gas out of the bike and let it sit there it hasnt moved not one inch since 97 till i moved it today ! the motor is locked tight i have tried penetrating oil to try to un stick the engine but it will not budge so i started taking it apart... now i must mention i have never owned a motorcycle never worked on one either !!! but know how engines work ! i took the gas tank, seat, airbox, and carbs today the carbs are super clean but i am still going to give them a good cleaning and soak !! My question is where should i go from here i know taking the head off but not to sure what to be looking for ?? so any info would be usefull as i would like to know the extent of the damage i like the style of the kz's and would like to make this a custom Kz !

Thanks in advance !

Thunder Lizard · 07-04-2009

pull the sparkplug, pour some oil in the top, and let 'er sit for a while.. a couple of tablespoons should be enough. Hopefully it's not seized completely, and the oil will help free up the pistons. I'm sure there's more and better advice coming, but that's always where I've started on any old engine, "stuck" or not.

herk · 07-04-2009

How long did you let the penetrating oil work it's magic?
I have no experience in unfreezing an engine, but I'd keep spraying it into the spark plug holes over the course of several days or longer. Hopefully, the bike wasn't kept outside & water hasn't gotten inside the cylinders because of missing spark plugs or disconnected exhaust or carbs.

Cadillac · 07-04-2009

I have tried several different penetrates, wd-40, pb blaster, and they have sit for a about 4 to 5 days, i keep putting more in it, the bike ran when he parked it it did sit outside but under a shelter with all parts attached.. the spark pulgs was still in the engine !

zeiss150 · 07-05-2009

12 years of sitting out side... I'd bet a dollar that the rings on one or more of the pistons is rusted to the walls of the cylinders. Even with the spark plugs, exhaust, and carbs on, water (or condensation more likely) will still get into the engine.

Pull the head and see what you can see... if its rusted you'll know... and if its not... well then you have a bigger problem.

If the pistons are rusted you'll need to figure out how to get them "unstuck" I saw some stuff at the auto parts store today that supposedly "freezes" the metal and that breaks the rust bond. Its worth a try I guess.

Once you get them unstuck you'll need to find replacement pistons, rings, and cylinders. Easier said than done. There is no NOS from Kawasaki for this bike. Ebay is your friend for rings and pistons you just need to keep any eye glued and wait for what you need to come up.

The other option is to buy a running KZ750 engine and swap it in for the 650. Its a direct swap and you can usually get a running engine for about $300... (I think).

Good luck and let us know how it goes!

Matt-

Cadillac · 07-06-2009

thanks for the info but i got it fixed today !!!!

i broke the engine down to the jug and you were right to a point there was a little rust but very little.. jus enough to stop one of the pistons at the top it was like a rust stopper but jus one little ring.. SO i cleaned it the best i could and beat it with the wood end of a hammer and wa-la no more problems engine is free !!

... I plan to clean it somemore and replace gaskets... flush the enigne and re assemble.. and hope for the best !

OKC_Kent · 07-06-2009

Would it be a good idea to make a few light passes with a hone?

07-04-2009	#1 (permalink)
Cadillac Newbie Join Date: Jul 2009 Posts: 8	78 Kz 650 sr ENGINE STUCK !?? What up first of all i am new... to the forums and the world of KZ's i picked up a Kz 650 sr from my friend for a 100$ but the engine is stuck i can not get it broke loose... the bike was a 1 owner but in 1997 dude got cancer and jus drained the gas out of the bike and let it sit there it hasnt moved not one inch since 97 till i moved it today ! the motor is locked tight i have tried penetrating oil to try to un stick the engine but it will not budge so i started taking it apart... now i must mention i have never owned a motorcycle never worked on one either !!! but know how engines work ! i took the gas tank, seat, airbox, and carbs today the carbs are super clean but i am still going to give them a good cleaning and soak !! My question is where should i go from here i know taking the head off but not to sure what to be looking for ?? so any info would be usefull as i would like to know the extent of the damage i like the style of the kz's and would like to make this a custom Kz ! Thanks in advance !

07-04-2009	#2 (permalink)
Thunder Lizard VROC #25645 BTK Expert Join Date: Jun 2007 Location: Calgary, AB Posts: 801	pull the sparkplug, pour some oil in the top, and let 'er sit for a while.. a couple of tablespoons should be enough. Hopefully it's not seized completely, and the oil will help free up the pistons. I'm sure there's more and better advice coming, but that's always where I've started on any old engine, "stuck" or not. __________________ To be a Rock, and not to Roll. '07 VN900 LT Blk/Slv "No Angel" My Ride

07-06-2009	#7 (permalink)
OKC_Kent Riding every day! BTK Expert Join Date: Sep 2005 Location: Oklahoma City Posts: 1,017	Would it be a good idea to make a few light passes with a hone? __________________ Oklahoma City '78 KZ 650 '83 KZ 750 Proud Marine Corp Dad

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07-04-2009	#3 (permalink)
herk bustedfeet BTK Expert Join Date: Jun 2006 Posts: 1,759	How long did you let the penetrating oil work it's magic? I have no experience in unfreezing an engine, but I'd keep spraying it into the spark plug holes over the course of several days or longer. Hopefully, the bike wasn't kept outside & water hasn't gotten inside the cylinders because of missing spark plugs or disconnected exhaust or carbs.

07-04-2009	#4 (permalink)
Cadillac Newbie Join Date: Jul 2009 Posts: 8	I have tried several different penetrates, wd-40, pb blaster, and they have sit for a about 4 to 5 days, i keep putting more in it, the bike ran when he parked it it did sit outside but under a shelter with all parts attached.. the spark pulgs was still in the engine !

07-05-2009	#5 (permalink)
zeiss150 Uncle Bob's Love Child BTK Expert Join Date: Jun 2007 Posts: 284	12 years of sitting out side... I'd bet a dollar that the rings on one or more of the pistons is rusted to the walls of the cylinders. Even with the spark plugs, exhaust, and carbs on, water (or condensation more likely) will still get into the engine. Pull the head and see what you can see... if its rusted you'll know... and if its not... well then you have a bigger problem. If the pistons are rusted you'll need to figure out how to get them "unstuck" I saw some stuff at the auto parts store today that supposedly "freezes" the metal and that breaks the rust bond. Its worth a try I guess. Once you get them unstuck you'll need to find replacement pistons, rings, and cylinders. Easier said than done. There is no NOS from Kawasaki for this bike. Ebay is your friend for rings and pistons you just need to keep any eye glued and wait for what you need to come up. The other option is to buy a running KZ750 engine and swap it in for the 650. Its a direct swap and you can usually get a running engine for about $300... (I think). Good luck and let us know how it goes! Matt-

07-06-2009	#6 (permalink)
Cadillac Newbie Join Date: Jul 2009 Posts: 8	thanks for the info but i got it fixed today !!!! i broke the engine down to the jug and you were right to a point there was a little rust but very little.. jus enough to stop one of the pistons at the top it was like a rust stopper but jus one little ring.. SO i cleaned it the best i could and beat it with the wood end of a hammer and wa-la no more problems engine is free !! ... I plan to clean it somemore and replace gaskets... flush the enigne and re assemble.. and hope for the best !

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