KZ305 Rebuild...attempt

The hard, deformed plastic at the oil pump end of the oil strainer.

 

The new strainer arrived, and... that ain't plastic. Well it is now but it used to be rubber. Glad I got the new one. I wonder if oil was seeping around the formerly rubber seal on the old one.

Gasket work is slow...but making progress. I can only stand it for about 15 minutes at a time. I've experimented with wd-40, carb and brake cleaner, acetone and Berryman's chem-dip and the latter works best but its still slow as snot. Hopefully I'll be done when the new piston walks here from Germany.






 

No eBay APP ID and/or Cert ID defined in Kunena configurationCrap...I just realized the piston rings I bought are not OEM...



I think it was the green background in the photo that lulled me into not even questioning it, but it clearly says aftermarket in the body of the ad. Not sure how much it matters and not sure I had any other options for NOS but I'm kicking myself for not noticing it before.

Should not be a problem.  You have what you have.

When you install them you need to ensure that the top and middle ones go in with the correct side facing up.  Your manual will explain.

I'm not even sure my piston has shipped. The German tracking site says

The item was handed over to the International Logistics Center on 07.05.2021 to be forwarded to the country of destination. Further information is also provided by the website of the country of destination.

and the country of destination site says

Your package is on its way to a USPS facility. Status. Origin Post is Preparing Shipment

Hmm, the first part could mean its on the boat but the 2nd part doesn't sound good at all.   

I had a message like that for about 3 weeks waiting for my last package from the UK - it's opaque, but probably okay. 

The piston has made landfall and will be here next week. Guess I better double down on the last bits of base gasket between the bores that I've been avoiding.

OK! My piston will arrive today, only 1 day late, which will hopefully coincide with me finally getting the nasty last bits of gasket off the cylinder base. If there is a part of this job that I never ever want to do again, its the gasket removal.

I have only glanced at what is to come-do I need to have anything special like piston pliers or anything else to get the rings on and the pistons back in their bores? I did see there is a section on how the rings should line up.

Ring pliers help but you should be able to install them without pliers if you're careful.  Just remember to install them with the correct side facing upwards.

wrote:

Great news - I found a mention with some photos of the blanking plug that causes issues. z250.co.uk/service.html

 

There's a PDF with some good info. I'm not 100% on the location still but with the photos I should be able to find it...and it seems it may be doable without splitting the cases. 


 

Where's that pdf? I can't download it now. I probably won't need it but I'd like to look at it.

wrote:

wrote:

Great news - I found a mention with some photos of the blanking plug that causes issues. z250.co.uk/service.html

 

There's a PDF with some good info. I'm not 100% on the location still but with the photos I should be able to find it...and it seems it may be doable without splitting the cases. 





 

Where's that pdf? I can't download it now. I probably won't need it but I'd like to look at it.

The "hidden" link to the PDF.

 

www.z250.co.uk/2008MCM.pdf
 

Thanks. i think I'm going to make my life easier and not do the plug at this time, but I appreciate you showing the way for later. I have enough doubts about getting this rebuild back together and up and running again without taking more things apart. Its really no big deal to do it at a later date if my rebuild is a success, and I can check my screen again at that time. I'm already starting to forget how things came apart (I have pictures and the manual) so I need to get it back together ASAP!

I'd kind of like to spray down the inside of the clutch cover and clutch area and cylinders before putting it all back on, just to make sure there's no dirt or debris hiding. Any recommendations on what to use? I've been using mineral spirits on the exterior parts but it doesn't always evaporate completely so I don't think that's a good idea. Anything else safe to use in this capacity? Carb cleaner maybe?