Sight glass nightmare

www.partzilla.com/parts/search/Kawasaki/...+A1-A2%29/parts.html

671B2590 "0" RING,90MM

Yes

OK i sort it out. I find a generic 90mm ring at the auto spares shop. It is fitted in place.
I checked all the stuff inside, relief valve, bypass valve, oring etc.
New bardhal 10w50 XTC (fullerene)
New oil filter and orings.

I was also missing the small washer on the filter spring. I put one that match with the filter rubber and the spring.
I started the engine and in about two second all the oil disappear from the sight glass.
I think i am a lucky guy.

Mine was clouded over and my IDIOT light would only work from time to time. Then I lunched a piston. That little voice told me to clean it, all it took was some Q tips, carb cleaner and my cordless drill to clean it. Bad connection in the main connector and that almost cost me the engine. THAT's why I have a gauge.
Steve

shamal wrote: OK i sort it out. I find a generic 90mm ring at the auto spares shop. It is fitted in place.
I checked all the stuff inside, relief valve, bypass valve, oring etc.
New bardhal 10w50 XTC (fullerene)
New oil filter and orings.

I was also missing the small washer on the filter spring. I put one that match with the filter rubber and the spring.
I started the engine and in about two second all the oil disappear from the sight glass.
I think i am a lucky guy.

Good work! Amazing really. I'm not sure exactly what would happen if the large O-ring was missing but I suspect some oil was able to bypass the oil filter. Finding the relief valve stuck open means you had very low oil pressure. Good thing you found that.

let me explain. in my bike the oil light is only about the LEVEL of oil in the engine. if oil have no pressure, or insufficient pressur, or something doesnt work.. you will not know anything.
the display in the instruments show a red blinking led when the oil is under the safety level. nothing about proper function of lubrication system.
this is why i was so scared. and , indeed, i was right.
now the lubrication system works.
i put some pictures about what i find in the sump after 200 miles from the rebuild.

in the metal screen i find something that is like a greasy gauze. once scraped seems to have the consistency of a very thin paper. what the hell was that???? :huh:

and some bit of metal scrapes, but i think this is ok.

the missing oring here. :blink: :blink: :blink: i wonder how i did not seized the engine without it...

opinion?

That metal swarf is likely remnant material left over after your crank disaster. The fibrous junk looks scary. Did you use paper towels to clean parts during the engine rebuild? That in itself shouldn't cause that sort of issue unless there was a lot of shedding and remnant paper material was remaining on the parts though.

The missing O-ring suggests someone inexperienced was inside the engine. Did you verify the presence of the three 92055-077 "O" RING's on the engine before installing the sump cover (#14 in the linked image)?

www.partzilla.com/parts/search/Kawasaki/...+A1-A2%29/parts.html

.

650ed wrote:

shamal wrote: let me explain. in my bike the oil light is only about the LEVEL of oil in the engine. if oil have no pressure, or insufficient pressur, or something doesnt work.. you will not know anything.
the display in the instruments show a red blinking led when the oil is under the safety level. nothing about proper function of lubrication system.

Who told you that??? That is not at all similar to how the stock oil light operates. I would urge you to buy a Kawasaki Service Manual so you can read about how the various systems on your motorcycle work. Here's what the Kawasaki Service Manual states;

Attachment not found

i have the oem manual. and yes, i'm sure i'm right. the sensor your talking about in the kz 550 is fitted in the sump, near the oil filter.
in the Gpz550 this is not fitted. there is just a ''sender level unit'' in the front part of the sump, just near the oil drain plug.......................

and yes, i have the 92055077 oring brand new. no paper towel. i think this is just grease. i coated the new oil pan gasket with a bit of grease during rebuild. i do not use sealant.

Ed this is the pressure switch. the gpz 550 h do not fit it. no holes in the pan. only oil level sensor. i know it is strange, but this is....

in this image you can see the hole in the front for what the manual call ''OIL level sender unit'' , no more thread for pressure switch. this thing is mad, anyway. i don't understand why kawasaki did that.

i.ebayimg.com/00/s/OTAwWDE2MDA=/z/b~sAAOSw8lBTmg2y/$_1.JPG

A fuel level sender is for a gas gauge on the tank, not the oil light.

R

sorry i mean to say OIL level sender unit. uhu.