My second Kz440 1981

As far as gasket removal, the permatex gasket remover helps to soften it up.



A green scratch pad, small brass wire brushes work well by hand. If you use a scraper be very careful. I use abrasive impregnated nylon wheels to take of gasket material. MAC tools sells them with different ones for cast Iron, or aluminum. I found some at a hardware store that work just as well for a fraction of the price. The blue ones are good for use on aluminum. I have had good luck with them.




To flush the engine out I buy the cheap ATF from Wal-Mart , poke a hole in the top and squeeze the bottle to spray around inside the engine cases. I know some people that mix ATF and Diesel as their general purpose "solvent" too. whatever you use its a good idea to get as much of the contamination out of the engine as possible before you button it back up.

Tyler wrote: As far as gasket removal, the permatex gasket remover helps to soften it up.

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A green scratch pad, small brass wire brushes work well by hand. If you use a scraper be very careful. I use abrasive impregnated nylon wheels to take of gasket material. MAC tools sells them with different ones for cast Iron, or aluminum. I found some at a hardware store that work just as well for a fraction of the price. The blue ones are good for use on aluminum. I have had good luck with them.

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To flush the engine out I buy the cheap ATF from Wal-Mart , poke a hole in the top and squeeze the bottle to spray around inside the engine cases. I know some people that mix ATF and Diesel as their general purpose "solvent" too. whatever you use its a good idea to get as much of the contamination out of the engine as possible before you button it back up.

Thanks, I will have to pick up some of that stuff on my way to work. When it comes to cleaning it out, my philosophy is that of clean it, clean it again, keep cleaning it till I am pretty sure it is clean, then clean some more. I would hate to damage the engine, because I decided to skip on the clean up.

Last night, I finally got the base gasket removed, for the most part. I will go over it again later. I needed to do something other than scrub gaskets off, so I decided it wouldn't hurt to start the first few rounds of flushing out the case. When I get home from work today, I will start on the clutch and alternator gasket, then flush it out some more.

I am really worried, I flushed out the engine a few times and found some fairy dust. Today, I removed the oil screen and felt sick.

Is this engine dead?

Is it magnetic?
Steve

Not magnetic

OK, have you taken the valve cover off yet? Might be a sloppy cam chain.
Steve

Strike that. Look for areas where the cam chain had been rubbing.
Steve

I have found little bits of crap like that after pulling cylinder blocks off.... sometimes grime, dirt, road trash and little itsy bitsy rock debris sticks deep in the cooling fin area and the jostling lets them fall down in the case. Later picked up in the oil pump screen.
Although upsetting at the time, I'm not so sure I'd loose much sleep over it now.

I looked over everything, I did see anything that would resemble the cam chain rubbing. I'm hoping it is just crap like missionkz suggested.

There was quite a bit of engine sludge when I started flushing out the inside. Maybe it is what 30 years of garbage and more than likely crap routine maintenance looks like.

Or previous problems the PO had. When you put it together, you'll know. How's the rods? Wiggle them and look for slop. They're plain bearings. That might be it. I hope not.
Steve

swest wrote: Or previous problems the PO had. .....
Steve

Yikes I didn't think of that.
I would just wash it all out and change the oil again in 350- 500 miles.