kz650 1978 Q/A

The rear axle can remove the flywheel on the early 650s.
Have removed a few this way.
Thread the axle all the way into the flywheel, then tap on the end of the rear axle.
Should come loose.

Regarding the engine cover gaskets, someone gave me this tip; spray one side of the gasket with Pam no stick spray.
Next time you remove the engine cover, the gasket won't tear, and can most likely be reused.

wrote:

Regarding the engine cover gaskets, someone gave me this tip; spray one side of the gasket with Pam no stick spray.
Next time you remove the engine cover, the gasket won't tear, and can most likely be reused.

I was worrying about leaks, not disassembly. Want to make sure it seals perfectly. Maybe just inspect surfaces very closely and in any doubtful places add little silicone?

Be careful to remove any trace of the previous gasket.  Don't use silicone tubes.  It's too easy to squeeze it into places where it shouldn't go.  If anything, just a little Permatex spray.

Cases been bead-blasted. All clean and perfect. No traces of old, no scratches. Definitely not using silicone nor overdoing it, I know better..
I was more curious about some kind of "spray" just to give gasket more "stick" and seal any smallest imperfections to prevent even sweating hopefully.

Maybe I am overly cautious because in my motorcycle engine experience with soviet motors - they all were leaking And 30 years ago we didn't have access to sealants, only paper.
 

2 new questions as I go carefully through everything.

#1. Rubber ball. I lost it. Is it's only purpose is to block oil channel? If so, I could just replace it with silicone plug, correct?

#2. #4 o-rings. Do the go on top of stud or under stud, not clear to me where it should be and what is the purpose? Only 2 studs?

 

wrote:

2 new questions as I go carefully through everything.

#1. Rubber ball. I lost it. Is it's only purpose is to block oil channel? If so, I could just replace it with silicone plug, correct?

#2. #4 o-rings. Do the go on top of stud or under stud, not clear to me where it should be and what is the purpose? Only 2 studs?

 

#1 = It´s not a rubber ball, it´s a formed kind of liquid gasket stuff that finds his way to plug your oil gallery/passage!!! The port have to be open to build up oil pressure for the cam bearing!!! Check all oil ports are free and not clogged with such kind of sh*t with compressed air!!!
#2 = i have no idea, please ask the 650 experts... 

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#1 = It´s not a rubber ball, it´s a formed kind of liquid gasket stuff that finds his way to plug your oil gallery/passage!!! The port have to be open to build up oil pressure for the cam bearing!!! Check all oil ports are free and not clogged with such kind of sh*t with compressed air!!!


 

Sorry, but you are wrong. It is rubber ball, see #14 on parts diagram. I held it in my hand and I have PN, just curious what it's for, need to be there.. It's not crankshaft, it's gearbox shaft.

 

Question #3

Parts diagram seem to be wrong on dowels, it's locations and qty.. I found some inaccurate places, but those on front back (#6) - I didn't have them, only on sides. Does it look correct?

 

Off subject but what are you soaking the case in?

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Off subject but what are you soaking the case in?

after blasting I washed in simple green solution to degrease. And then 350F oven. Per cerakote instructions. Tried to get is as clean as possible. Simple green pro won’t darken aluminum

CMS has that part in stock.

Those 2 o rings #4 go at the bottom of the #3 stud (next to #3 piston and cam chain opening). If you look you will see a cut out for them to fit into. Keep that rubber ball away from the bearing for sure. I can't really help you on its location or help with the dowels (didn't split the case) but if you look at the diagram at Partzilla it shows those 2 #6 dowel pins and they sell them.