KZ1100 A2 - My oil filter cover broke

Okay so I decided to rebuild my parts bike a 1982 KZ1100 A2. Everything was going fine, heads on, carbs on, electrics done, oil filled... Started the bike and it's oil filter cap broke into 4 pieces. Man, I was worried so I grabbed a spare cover I had on hand and in the mean time finished more on the bike. This am I started it and immediately noticed oil seeping from below. Upon checking, I noticed the O-ring didn't seat properly. After reseating the O-ring, I screwed the oil filter back on, torqued it to 14.5 ft lbs. I could see the O-ring between the cover and the oil pan, but didn't think anything of it. Well I started it up again, idled for a few seconds when the oil pressure light went on and there was oil on again. Upon checking, the oil cover this time broke like the first one, in several pieces. I've been on Ebay and ordered up a used oil filter bolt, cover and O-Ring. It'll be here in a couple of days.

So my question is, what the heck happened both times? I'm guessing it wasn't seated properly, but I'm wondering if anyone had any experience or even heard of such an occurrence.

Usually I just lurk here, but after searching I didn't find any answers.

Thanks in advance

edit: Forgot to add the make and model at the end

1982 Kawasaki KZ1100 A2

You may want to check your torque wrench to ensure it is still accurate. Ed

Thanks Ed. I will definitely do that, but after the pieces dropped out I was able to screw in the bolt 2-3 turns by fingers.

Looks kinda weak. You shouldn't see the O ring. Is the other one stuck on the pan or in the cover?
Steve

What brand of oil filter?

Hey Steve, the other pieces of the cover? They are on the ground, those where setting on the oil drain.

Nessism, the oil filter was Emgo I picked up from Z1

Okay, so my ebay oil filter cap came yesterday. In the mean time I took the oil pan off, cleaned the gunk out of the oil pump and got everything reassembled. This morning, I made sure the oil filter bolt and cap properly seated, the oil filter gaskets in place and mounted the oil filter, hand tightened it and used a in-lbs torque wrench set to 80 in-lbs to seat it, just to make sure it wasn't over tightened. Also made sure the cap was securely mated to the oil pan. Started it up ran a few seconds and turned it off, as you can imagine I'm a little gun shy of the oil cap problem. Checked for leaks, nothing. So I decided to start it again and let it idle for a minute and sure enough the new cap was broken again. What in the world is going on!?

Does ANYBODY have any idea what is happening? I'm at my wits end and considering just taking it to the salvage yard.....

Edit: The only thing I could find wrong was after checking the wiring diagrams, cylinders 2 and 3 had the wrong leads at the coil, 2 had the red wire and 3 had the green. I doubt that had anything to do with this problem.

I wonder if the filter it the wrong height or diameter which might cause undue stress on the cover when it is tightened? According to www.powersportswarehouse.com/pages/oempa...00-A2-1982/070065C-9 your KZ1100-A2 uses the same oil filter (part number 16099-003) as my KZ650-C1. As shown in the pictures below, the stock filter's diameter is 3 inches, and its height is 2 3/16 inches. You may want to check your filter to ensure it is the correct size. Also, double check that all the oil filter related pieces shown in the link above are in place and in the proper order. Ed

By the looks of it that seems to be a inherent problem. Looks weak to me. Does the spring go all the way to the bolt head? Mine doesn't and the fins are larger. I cranked mine down to compress the pan against the case so the O ring would compress. Maybe one from a earlier model KZ 1000 would work. Pics of the filter, bolt and spring?
Steve

Maybe show the height of your filter and also the order of the parts stack that fits on the filter bolt stem. Maybe the order of assembly is off somewhere? Filter installed up side down?

Edit: looking at the parts fishe on Partzilla and the assembly order seems simple...spring, washer, filter, and lastly the sheet metal umbrella piece that fits over the filter. I'm not sure which way up the filter needs to be installed. Is there a top and bottom? Could be the filter is the wrong size. That's one reason I do not like purchasing aftermarket parts.

Edit 2: on the 750/4 the embrella piece goes on first, so it's under the filter, not on top like the 1100. Go figure?

The filter can be installed with either side up. Ed

I am done!!!