bottom end

be very care with glassbeading internal engine parts including inside of cases,glass beads will actually imbed themselves into the aluminum and come out at later time as parts expand/contract and get washed down with oil.

Before you paint that oil pan, that long oil galley towards the upper right in your picture should have a plug in it? I have been thinking about installing an oil temp gauge, and that would be a great location for the sending unit.

finally split the cases. Someone has been in there with the overdose of orange RTV. The starter clutch just fell apart when I pulled it out. There is a plug installed there, but I think I'll skip the sensor at this point

yeah ya gotta use a little commonsense whenit comes to assembling things,unfortunately there are too many guys who just like throwing things together !

when I pulled the cams out, there were little bits of orange RTV trying to make it from the oil passage into the cam journal. It was everywhere. But its coming right off easily. I like yamabond (yes on a kawasaki)

Why not use KawasakiBond?? Yep, they've got it available through your dealer. Or maybe just pay less, buy the original stuff from ThreeBond under their number 1104 which has recently been changed up to 1194. Same stuff but cheaper than having the brand y or Kawasaki label on it.

Here are additional reasons manufacturers like to use to plain bearing cranks:
1) they are cheaper to manufacture because they can be mostly finished in NC machining equipment and require NO expensive hand labour to assemble them.
2) plain bearings can handle FARRRR more dirt in the oil than ball/roller bearing cranks. Ball/roller bearing cranks fail quite quickly (relatively speaking) if their oil is not changed religiously. This means that for the average owner who is NOT into spending time/money on proper maintenance the plain bearing crank is the way to go.

Wholly Crapola... Did the PO use (go over board) some gasket making material or what.... :blink: RTV???

Friggin aye, it's every where... :S

Very cool image for I have never seen the 650 lower end apart so now I understand in other postings where they were speaking of regarding main drive chain... I was like huh.... Now I know....

OMR

Old Man Rock wrote:

Wholly Crapola... Did the PO use (go over board) some gasket making material or what.... :blink: RTV???

Friggin aye, it's every where... :S

Very cool image for I have never seen the 650 lower end apart so now I understand in other postings where they were speaking of regarding main drive chain... I was like huh.... Now I know....

OMR

yeah some people are natural born idiots,there should be a competancy(spell check) test given before you can buy a tube of silicone!:laugh:

ok its out, and other than being dirty it looks good. Journals look good, no heavy wear patterns.

another view

here is the starter clutch, every time I just look at it, parts fall out...

Man, that starter clutch has some issues! How many parts fell out? Why are the bolts elongating the cover? Were all three rollers, springs and guides in there? Must be some serious flat spots on the starter gear!

I've another question on the primary chain. When we did the motor on my son's 650, the chain seemed like it had too much play. The FSM said 27mm allowable slack and we were in tolerance. The thing is noisy at idle even with spot on carb sync. My question is how much slack in present when a brand new chain is installed?
Keep the pictures coming! Ride safe, Steve