KZ305 Rebuild...attempt

As I remember Brake cleaner worked pretty good when spraying the inside of my motor out.

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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?
 

There's a purple version of Simple Green that is safe for aluminum AND for aluminium.


 

Chlorinated brake cleaner works a treat, but be sure to have plenty of ventilation and wear goggles.

OK, the "easy" part is done, now putting it back together! Let the troubles begin!

Getting some resistance putting the clutch cover back on and I'm not sure why. The oil pump drive gear is plastic so I don't want to force anything...but it seems to be engaging with the oil pump just fine, so don't know what else it could be...hopefully I'll have it figured out before you see this.

the manual is sooooooo helpful.   It says "make sure the 2 knock pins are in place and fit the cover on the crankcase". 

Gee thanks. Well there is obviously more to it than that you stupid manual because it aint going on! 

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Chlorinated brake cleaner works a treat, but be sure to have plenty of ventilation and wear goggles.
 

Due to the plastic oil pump gear I decided to just clean and vacuum as well as I could by hand. I wonder if electrical contact cleaner would work though...supposed to not hurt plastic.

I'm completely stumped on this cover though. Something must not be lining up, but what? Its not the knock pins, it has to be something hanging up around the clutch basket...or something...

Photos?

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Photos?

 

Not sure what there is to see. It looks just like the pic ghostdive posted above:


But now looking at that gives me an idea. The removable plastic gear that drives the oil pump (oil pump at lower right) has another, stepped gear that runs off the other steel gear above the oil pump in the picture. I'll bet I have to install that plastic gear by hand on the engine THEN slip the clutch cover on over it, and I've been trying to slid the cover on with that plastic gear in the cover (which is how it came off).  Its likely that it was engaging with the oil pump properly but not the other gear, which is much harder to see through the crack when I'm putting it on. I'll try that and report back.

Damn. Well it wasn't the plastic gear, so that only leaves the clutch connection/actuator whatever its called. And thats the area the resistance seems to be coming from. Other than continuing to jiggle it and try it in different positions I don't know what else to do. But no more tonight.

I was hoping to see what was sticking out and preventing the case from fully mating.  

Sometimes I find that disassembling and re-assembling will solve a problem like this.  Follow the manual carefully when re-assembling.

I bet it's a clutch pusher rod. Check cable/tensioner/

Assuming you haven't gotten it on yet...gonna say it's the clutch actuator. When the clutch is engaged, the lever on the clutch cover is about perpendicular to the mating surface - both times I've put the cover back on I rotated the lever to point backwards (extra not-pulled) and then fiddled back and forth while trying to get the cover seated. It's kind of annoying. 

I think aside from that, there's just the two dowel pins and the oil pump gear that could keep the cover from seating. 

wrote:

Assuming you haven't gotten it on yet...gonna say it's the clutch actuator. When the clutch is engaged, the lever on the clutch cover is about perpendicular to the mating surface - both times I've put the cover back on I rotated the lever to point backwards (extra not-pulled) and then fiddled back and forth while trying to get the cover seated. It's kind of annoying. 

I think aside from that, there's just the two dowel pins and the oil pump gear that could keep the cover from seating. 
 

yup, I just got it on came back in and saw your message. We are thinking the same things at the same time.

I hadnt taken the cable off of the clutch cover and it must have moved position since I removed it. I just had to line it up properly again and all is well. The reassembly has begun.