Mission Cover, KZ650

I just picked up a nice 1980 KZ650 LTD. I knew it was leaking oil. I was prepared to replace some oil seals. After closer inspection, I see the clutch pushrod is bent, and there is a 1" x 1/2" hole in the mission cover, right below the pushrod!!(see pic)
What would cause this, a broken chain? Anybody else experience anything like this??
Anybody know where to pick up a new mission cover & clutch pushrod?

Try www.oldkawman.com , www.redlinecycle.com , www.sudco.com , www.dynoman.net , www.vintagecyclepart.com , www.z1enterprises.com , www.partsnmore.com , and www.kzzone.com Some body should be able get/know who has this part.

As for bending the push rod for the clutch, it sound like a broken chain did the damage. www.z1enterprises.com sells replacement push rods.

Since all the following models use the exact same cover (according to kawasaki.com), I doubt you will have a hard time finding one

I probably have several spares laying around.


KZ550-A1 (1980)
KZ550-A2 (1981)
KZ550-C1 (LTD) (1980)
KZ550-C2 (LTD) (1981)
KZ550-D1 (GPz) (1981)
KZ650-B1 (1977)
KZ650-B2 (1978)
KZ650-B2A (1978)
KZ650-B3 (1979)
KZ650-C1 (Custom) (1977)
KZ650-C2 (Custom) (1978)
KZ650-C3 (Custom) (1979)
KZ650-D1 (SR) (1978)
KZ650-D1A (SR) (1978)
KZ650-D2 (SR) (1979)
KZ650-E1 (LTD) (1980)
KZ650-F1 (1980)
KZ650-H1 (CSR) (1981)
KZ650-H2 (CSR) (1982)
KZ750-B1 (1976)
KZ750-B2 (1977)
KZ750-B3 (1978)
KZ750-B4 (1979)
KZ750-E1 (1980)
KZ750-E2 (1981)
KZ750-E3 (1982)
KZ750-G1 (LTD II) (1980)
KZ750-H1 (LTD) (1980)
KZ750-H2 (LTD) (1981)
KZ750-H3 (LTD) (1982)
KZ750-M1 (CSR Twin) (1982)

hey steell, if you've got a cover & pushrod in decent shape, I'd like to buy em off ya. I don't know what else they fit, but I know the part #s are 13116-035 + 14024-011. If you need more pics, or measurements, I can provide them (I got a micrometer & dial caliper).
Do you think any other damage was caused? The bike runs great. I'm getting ready to drain the oil soon..
UPDATE
Hey Steell, sorry, I was not familiar with that part of Kawasaki.com. Now I see you are right about all those models fitment.
I drained the oil, didn't find any metal filings or anything like that, so that is great! However, I did find some water in the oil, but after some thought, I realized that was from me washing/degreasing in there to find the oil leak. I have not run it since rinsing it, so I am relieved about all that - maybe I'll even be able to get some sleep tonight...not betting on it though..anyway, I would still like to but that stuff off you, if you will help me out - THANKS!

The spare transmission covers would be off KZ750B twins, so I don't think any clutch pushrods I have will help you.

Amazing! The 750B twin pushrod is the same as yours, who'd a thunk it!

(Just checked kawasaki.com)

I'm a little confused; you're saying the mission cover would fit, but not the pushrod?

Wild and KZ Guy wrote:

I'm a little confused; you're saying the mission cover would fit, but not the pushrod?

No, I'm saying that (according to kawasaki.com) both items from a 750B will fit your 650.

Since the 650 is a four and the 750 is a twin, I find that surprising.

Surprising, & excellent!
I did without a motorcycle for about 20 yrs - married, lost the nerve, etc. But now I'm back into it. Anyway, I guess it's kinda weird - my last bike back then was a KZ750 twin.
I'm probably gonna close up for tonight, hope to talk to you tomorrow, either here, or - I'll check my private messages also. Thanks steell

I can't believe the cover and rod from a 750 twin are the same parts as a 550 four. Gotta like kawasaki for that.

Anyway, I went through that same thing last spring on my 550. I had a spare pushrod and cover. (Previously a race bike that the chain snapped on.) You should plan on replacing the 3 seals (output shaft, clutch rod, and shifter) and the cover's gasket. I found them all at Power Sports pro

The seals were about $3.60 each and the gasket was about $6.
Double check these numbers to cross with Kawasaki (because I bought a bunch of seals, but I think these were the numbers.)
11061-1090 gasket
92049-1017 seal
92049-1506 seal
92051-005 seal

(Some of the seals were replaced with upgraded versions which carried new numbers. If you click on the question mark or something on the Kaw site, I think it shows superseded numbers.)

Make note of how the seals go in before removing the old ones. Also note how far in the seals are set. They don't all have stops.

Hey thanks Loudvhx, for the seal tips! Any tips on removing those seals? Do they come out pretty easy?
Yeah, that's great, all those models being compatible, definiteley helps keep our old KZs on the road :[]
I was actually able to order all the seals and the gasket from Kawasaki ($50 total, I probably overpaid, but at least they'll be OEM parts); they came in yesterday, pick em up tomorrow. But I probably wouldn't have take notice of the depth, thanks again.

Yeah, they all push out fairly easily. One or two may only come out in one direction but the rest can go all the way through. I think I used an appropriate size socket or some other pushing tool to make sure to push the seals only around their edges.

The hardest part was getting the cover off (and cleaning all of the gasket material). There are pins holding it, so you can't just whack it with a hammer or pry it off. I attached some scrap metal to the sprocket protector bolot holes to form a handle. Then I used a lever to try to pull the cover straight off using the handle. I did tap it lightly with a nylon mallet just to break the gasket seal first. But after that I only pulled straight off. (This was on the replacement part. I didn't care what happened to the broken cover I was replacing.)

I wish I would have snapped a few photos.

Good luck.

Thanks for all the help & tips you guys. I was able to get it going today, no leaks I'm proud to say. All the seals went in fairly easily except the shifter one, that one took some extra patience.
Special thanks to Steell for helping me out!