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Removing lower crankcase - KZ550
- Pagala
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08 Oct 2019 06:55 #812055
by Pagala
1̶9̶8̶3̶ ̶K̶a̶w̶a̶s̶a̶k̶i̶ ̶G̶T̶5̶5̶0̶ ̶(̶U̶K̶-̶o̶n̶l̶y̶ ̶m̶o̶d̶e̶l̶)̶,̶ ̶a̶l̶s̶o̶ ̶k̶n̶o̶w̶n̶ ̶a̶s̶ ̶t̶h̶e̶ ̶Z̶5̶5̶0̶ ̶G̶1̶,̶ ̶r̶e̶g̶i̶s̶t̶e̶r̶e̶d̶ ̶i̶n̶ ̶1̶9̶8̶4̶.̶
1981 Kawasaki Z440 (KZ440C1)
Removing lower crankcase - KZ550 was created by Pagala
I need to replace my transmission output shaft. Is it possible to turn the engine upside down and lift out the crankcase bottom without removing the clutch or loosening the clutch nut, without removing the sump and oil pump,and without removing the secondary clutch and starter clutch?
1̶9̶8̶3̶ ̶K̶a̶w̶a̶s̶a̶k̶i̶ ̶G̶T̶5̶5̶0̶ ̶(̶U̶K̶-̶o̶n̶l̶y̶ ̶m̶o̶d̶e̶l̶)̶,̶ ̶a̶l̶s̶o̶ ̶k̶n̶o̶w̶n̶ ̶a̶s̶ ̶t̶h̶e̶ ̶Z̶5̶5̶0̶ ̶G̶1̶,̶ ̶r̶e̶g̶i̶s̶t̶e̶r̶e̶d̶ ̶i̶n̶ ̶1̶9̶8̶4̶.̶
1981 Kawasaki Z440 (KZ440C1)
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- Daftrusty
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08 Oct 2019 07:53 #812062
by Daftrusty
1990 zr550
kz750e
650/750 6-speed Transmission Swap
Replied by Daftrusty on topic Removing lower crankcase - KZ550
No is the long and short answer.
To split the cases, the secondary shaft and starter clutch HAVE to come out. To get those out you have to remove the clutch in its entirety and the oil pump.
The crank, rods, pistons, cylinder block and head can stay in place.
To split the cases, the secondary shaft and starter clutch HAVE to come out. To get those out you have to remove the clutch in its entirety and the oil pump.
The crank, rods, pistons, cylinder block and head can stay in place.
1990 zr550
kz750e
650/750 6-speed Transmission Swap
The following user(s) said Thank You: Pagala
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10 Oct 2019 14:56 #812198
by Pagala
1̶9̶8̶3̶ ̶K̶a̶w̶a̶s̶a̶k̶i̶ ̶G̶T̶5̶5̶0̶ ̶(̶U̶K̶-̶o̶n̶l̶y̶ ̶m̶o̶d̶e̶l̶)̶,̶ ̶a̶l̶s̶o̶ ̶k̶n̶o̶w̶n̶ ̶a̶s̶ ̶t̶h̶e̶ ̶Z̶5̶5̶0̶ ̶G̶1̶,̶ ̶r̶e̶g̶i̶s̶t̶e̶r̶e̶d̶ ̶i̶n̶ ̶1̶9̶8̶4̶.̶
1981 Kawasaki Z440 (KZ440C1)
Replied by Pagala on topic Removing lower crankcase - KZ550
Awesome - thanks. I haven't lifted a finger to do anything yet, I'm just getting my head around what I need to do, and plan the operation. I'm also buying the relevant gaskets and seals.
One more question: to rejoin the 2 crankcase halves, would Hylomar Blue (non-setting jointing compound) be sufficient, or would a copper-based gasket-making compound be more suitable? The workshop manual says to put "sealant" almost all the way around the mating surfaces, but it doesn't say what type.
One more question: to rejoin the 2 crankcase halves, would Hylomar Blue (non-setting jointing compound) be sufficient, or would a copper-based gasket-making compound be more suitable? The workshop manual says to put "sealant" almost all the way around the mating surfaces, but it doesn't say what type.
1̶9̶8̶3̶ ̶K̶a̶w̶a̶s̶a̶k̶i̶ ̶G̶T̶5̶5̶0̶ ̶(̶U̶K̶-̶o̶n̶l̶y̶ ̶m̶o̶d̶e̶l̶)̶,̶ ̶a̶l̶s̶o̶ ̶k̶n̶o̶w̶n̶ ̶a̶s̶ ̶t̶h̶e̶ ̶Z̶5̶5̶0̶ ̶G̶1̶,̶ ̶r̶e̶g̶i̶s̶t̶e̶r̶e̶d̶ ̶i̶n̶ ̶1̶9̶8̶4̶.̶
1981 Kawasaki Z440 (KZ440C1)
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- Daftrusty
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10 Oct 2019 16:58 #812213
by Daftrusty
1990 zr550
kz750e
650/750 6-speed Transmission Swap
Replied by Daftrusty on topic Removing lower crankcase - KZ550
Use Kawabond, Hondabond, or Yamabond non-hardning sealant to seal the cases. Use a thin layer. Do NOT goop it on.
Get a manual for your bike and read it 2-3 times before you attempt what you are attempting.
Good luck and have fun!
Get a manual for your bike and read it 2-3 times before you attempt what you are attempting.
Good luck and have fun!
1990 zr550
kz750e
650/750 6-speed Transmission Swap
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