Base gasket leaking on 1983 KZ1100 ltd....

Hi guys...

I wonder if you can help me out here. Last summer I successfully cured the oil leaking from the head on my bike, fitted two new head gaskets, and the rectangular shaped o-ring. All was well, but then I noticed oil weeping from the base gasket after a run, along with a good lubricating of my boots... I must have disturbed the cylinder block while removing the head.

I have the Kawasaki works manual and it shows a factory ring compressor clamped on all four cylinders. Now, I haven't got one of these, and was wondering if you guys have any tricks/tips for me to accomplish this job efficiently and successfully. At the moment I can't think for the life of me how I'm going to manage to drop the cylinder block over all four pistons single handed.

Thank you and here's hoping .... Dave

Lots of people use hose clamps as mickey mouse ring compressors.

Depends on whether the gasket is torn up or still physically intact but leaking. A lot of times the base gasket tears when you lift the cylinder up, if not you might be able to seal it.

You MIGHT be able to raise the cylinder up an inch or two without releasing the rings. Use small vise grips clamped to the studs to hold the head up and apply 3-bond to the base gasket.

Have you tried to retorque the head?

I have tried a few different ring compressors but nothing works better than my fingers. There is a bit of taper on the base of the cylinder liners. Just use a clamp on the cylinder studs or a piece of wood etc to support and incrementally lower the cylinders as you feed the rings.

Thanks guys, I appreciate it.

I tried re-torquing the head but to no avail. You've given me something to think about though re jubilee clips and clamping the studs to let the block down slowly though. That's good news on the cylinders being tapered at the bottom too.

I've got to admit I've been dreading doing this job. I'm a pretty handy mechanic, but for some reason I've probably built this up to be a bigger deal than it is. Pretty simple popping the pistons in a car block from the top, but easing all four in from the bottom from a suspended cylinder block has been what's bugging me I think...

One thing I will say while here. A mate said something about cutting some old beer or coke cans in half and using those as clamps... ever heard or tried anything like that?

Thanks anyway, I appreciate your time... Dave

Where is the leak on a front corner or rear? I have a fix if it is leaking from the front, it requires removing the head but you can leave the cylinders alone.

That's why anytime anybody talks about replacing a head gasket on here they always hear a little voice in the background that sounds a lot like mine,it wispers something like this:
ANYTIME YOU REPLACE A HEAD GASKET,REPLACE BASE GASKET AT SAME TIME! :woohoo:
For all the time and money it takes to replace a head gasket once,it sucks even more the second time. :blink:

Remember to order the O-rings for base of 4 outside studs when you order the gaskets

Cheers guys...

Baldy, it appears to be coming from front left corner if you're sat on the bike, same side as gear shift.

Wireman, its sucking al-right :S Still, you live an learn, I'm looking at it as character building. Regarding those 4 O-rings on the outside studs, would they be the same as the 4 outside ones under the cylinder head? Also, what's this I hear about different material base gaskets with different thickness's...? I knew it wouldn't be that simple... :woohoo:

Bountyhunter, I like the thought of being able to get some seal in there, but what worries me a little is the space to clean up properly prior to sealing, and then of course putting it all back together and its still leaking. Still, that's my cross to bear.

I'm very grateful for the input from everybody, it definitely helps to make the job less daunting.

I'm off to get some kip now, got an early start in the morning... 10.30pm UK time.

Dave...

Yes those are the same O-rings

wireman wrote: Remember to order the O-rings for base of 4 outside studs when you order the gaskets

yea...i learned that today!

saxonpirate wrote: ...I have the Kawasaki works manual and it shows a factory ring compressor clamped on all four cylinders. Now, I haven't got one of these, and was wondering if you guys have any tricks/tips for me to accomplish this job efficiently and successfully. At the moment I can't think for the life of me how I'm going to manage to drop the cylinder block over all four pistons single handed....

Some ideas --
www.kzrider.com/forum/advsearch?q=piston...ldforums=1&catids=21

Good Fortune!

natetru wrote:

wireman wrote: Remember to order the O-rings for base of 4 outside studs when you order the gaskets

yea...i learned that today!

Sorry to interrupt but I need to know more about this.
Wireman you're saying to put 4 o-rings under the cylinder block in addition to the ones on top of the cylinder block? I don't see these on the parts diagram... :huh: