Aluminum Cam End Plugs

Scirocco wrote: In some rare cases...you have to do a little rework on the plug to fit in.
I speak of experience, i had to do it in my case.
The cam end plugs ( the Kawasaki rider here in Germany call them half moons ),normally fits so tight that you can use any kind of liquid gasket ( very thin layer of Hylomar blue ). They never come loose if i pull my valve cover to do a valve job .



Michael

Thanks for the heads-up. I expect some minuscule inletting if the fit is a little snug, and then the tops must be flush with the gasket surface...:pinch:

I installed the same ones a few weeks ago. A word of advice. MAKE SURE you pre-fit them both with and without the valve cover on!!! I had 2 that fit perfectly, but the other 2 the holes were off size just a bit, and the bolts wouldn't go thru. I haven't fired it up yet to check for leaks. I used the copper goo cause that's all I had. Wish both of us luck!!!

havakaw wrote: I installed the same ones a few weeks ago. A word of advice. MAKE SURE you pre-fit them both with and without the valve cover on!!! I had 2 that fit perfectly, but the other 2 the holes were off size just a bit, and the bolts wouldn't go thru. I haven't fired it up yet to check for leaks. I used the copper goo cause that's all I had. Wish both of us luck!!!

Same as these?
i.ebayimg.com/images/g/nEAAAOSwHQ9WaGyE/s-l1600.jpg


They arrived from Germany yesterday, and I took them to the man-cave for close examination and comparison to the stock ones we all love so-well.

These alum plugs are quite different in appearance and shape. Also, they are thinner which pulls the face back under the cover by approximately 1/32", so they will not flush out with the cover as I had hoped.

Havakaw, please post a couple pics of the installation on your engine.


Edge-edge comparison:






Misalignment of alum. plug with old ratty cam cover:



Correct alignment of Genuine Kawasaki, though they do migrate out-of-alignment after tightening and quick passage of time:

I used Ducatibond on my cases, Hondabond and Yamahabond I guess very simlar, in Grey or black.

You could even be contoversial and try some 92104-1003 Kawibond.

Those pics show what I suspect was my problem. On one side of the haed, everything fit and lined up perfectly. On the other side, the bolt holes were off a bit, and I didn't notice untill I had the valve cover on and all bolted down. I ended up drilling the holes out in place and runing a tap thru just to make sure it was good. Sorry no pics from me. I got a flip phone. Maybe when I get the Delkevic on it I'll have my girl take the pics and upload them. Sent you PM about those clamps if you still have them.

Thanks for the assessment. This may be a can of worms, which I'll regret opening.
If I do end up fitting them, I will photo-document for anyone interested.

Regarding the SS carb-manifold clamps...$25 shipped in USA

Two plugs fit without having to open the holes up, but the other two...:evil:





I'll need to remove approximately .5 mm to get every plug to flush out with the cam cover gasket surface.
...then blend the return-bevels to align with the cover end flats above.
These plugs polish up real nice.

Not sure about this, but it appears the gap at the base of the plug indicates that the curved head surface tapers away at the outside, so the plugs likely rest on the inside edge. If so, then this will assist to expel excess Hylomar () sealant toward the outside where it can be cleaned off much-easier than inside where there is very-little access space next to the cams. :blink:

PITA x 4 = :evil:

Whew, some project this [strike]was[/strike] is. :S



First try. Hopefully, no leaks for awhile. :whistle:

Nice!

After the first ride...found a little oil drip at the bottom of half-moon #1. :pinch:
It crept around to the front of the plug, and was sitting there all proud of itself until I wiped most of the memory away with a rag. The cover gasket is sealed up nice, as are the three other plugs...

Wondering about using the cover gasket again...it's a plain OEM Kawasaki gasket with no graphite that should clean up well.
What should I wipe it down with?

Sorry to read about your failure with the half moons after all your hours of work and sweat.
What kind of liquid gasket do you use?
My half moons never do leaking after i have to do a little reshape with a key file in 1998 to get a little tight fit plus Hylomar blue.
My engine is dry like a dessert except the cam chain tunnel area and stator grommet.