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KZ550 Head Gasket 06 Jul 2015 17:46 #679757

  • nickleo373
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I've decided to just go ahead and try to replace the gasket myself. Does anyone have any advice that isn't in the Clymer manual before I get started? Also I've been trying to find a link for a replacement head gasket and cant seem to come up with one on Ebay. Anyone know where to find one?
1981 KZ550C LTD
"If you ain't first, you're last"

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KZ550 Head Gasket 06 Jul 2015 17:49 #679759

  • missionkz
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Some good advice would be to get a real Factory Service Manual... FSM.
Go to Google and do a search for your .... KZ550 head gasket ....
SIMPLE......
Sort of like this:
www.cmsnl.com/1980-kz550-a1_model15477/h...041212/#.VZsfdEZOySo
Bruce
1977 KZ1000A1
2016 Triumph T120 Bonneville
Far North East Metro Denver Colorado

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KZ550 Head Gasket 06 Jul 2015 18:21 #679773

  • SWest
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Yeah, that's a one piece gasket. No O ring to fail and puke oil all over your leg. God I hate that. :evil:
Steve

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KZ550 Head Gasket 06 Jul 2015 18:42 #679782

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Look under "Loudhvx" s profile.............. he has a factory manual you can down load, along with tips and warnings on the KZ550 !!
1978 KZ650 b-2
700cc Wiseco kit 10 to 1.
1980 KZ750 cam, ape springs, stock clutch/ Barnett springs.
Vance and Hines Header w/ comp baffle and Ape pods, Dyna S and green coils, copper wires.
29MM smooth bores W/ 17.5 pilots, 0-6s and 117.5 main
16/42 gearing X ring chain and alum rear JT sprocket.

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KZ550 Head Gasket 06 Jul 2015 19:06 #679793

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VERY IMPORTANT
Steve

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KZ550 Head Gasket 06 Jul 2015 21:14 #679838

  • PLUMMEN
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Id do a leak down test on it 1st before pulling the head off to get a general idea of the condition of the rest of the motor
If the rings are still sealing Id atleast have the head cleaned up while its apart and do a valve job and new guide seals. ;)
Still recovering,some days are better than others.

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KZ550 Head Gasket 06 Jul 2015 21:31 #679841

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Yup
Steve

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KZ550 Head Gasket 07 Jul 2015 05:24 #679866

  • Tyrell Corp
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As above, some further diagnostics, maybe a wet and dry hot compression test whilst it is still running before you tear it down would make sense. One last try maybe after tourquing your head, do it again once it is cold.

The UK Haynes manuals are pretty good, particularly on the top end rebuild, if you can find one there. I'm going to be doing this on my 550 very soon so I'll stat a thread on it with pics of the rebuild.
1980 Gpz550 D1, 1981 GPz550 D1. 1982 GPz750R1. 1983 z1000R R2. all four aces

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Last edit: by Tyrell Corp.

KZ550 Head Gasket 08 Jul 2015 13:31 #680058

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Thanks for the replies. I downloaded the factory manual and did a compression test on the engine. The compression test turned out good so there's no need to rebuild anything inside. I finally got the cover off the side of the engine to turn it to tdc to begin and I noticed what's inside looks different than what the manual says is supposed to be inside. There are no timing marks anywhere. Can anyone tell me what I'm looking at?
1981 KZ550C LTD
"If you ain't first, you're last"
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KZ550 Head Gasket 08 Jul 2015 13:45 #680060

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I always look inside those oval shaped holes for timing marks
Bruce
1977 KZ1000A1
2016 Triumph T120 Bonneville
Far North East Metro Denver Colorado

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Last edit: by missionkz.

KZ550 Head Gasket 08 Jul 2015 14:59 #680071

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Yes, the timing marks and the TDC mark are on the rotating mechanism seen through the upper oval. There is also a pointer cast into the aluminum portion of the housing seen through the same oval. The manual should show a picture of that, but it may be in the appendix for later models, depending on what manual you are actually using. There are several in my signature if you need to compare.

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KZ550 Head Gasket 12 Jul 2015 17:05 #680584

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I adjusted the timing to tdc through that hole and now I made it to the head gasket. I took it off and it left a little bit of oil staining and residue on the mating surface. I'd like to use a gasket remover to take the remaining pieces off. Would the tops of the pistons be effected by gasket remove spray or is it safe to use?
1981 KZ550C LTD
"If you ain't first, you're last"

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