Assembling the split cases
- Vietvet
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Assembling the split cases
08 Oct 2026 23:53
Hi, I am at the stage where I can assemble the split cases on my "79 KZ650 B3.What is the best way to do it I have had a couple of dry runs not using the 3 Bond that I have and I seem to be having trouble lining everything up. The manual I am working from talks about putting the bead of sealant on the bottom case and then fitting the bottom case onto the top case. Number 1 it is too heavy for me to lift and jiggle it about and what is stopping the gears letting go. Doing it the other way seems more practical to me but it would be nice to have 4 arms and hands to stop the cranks flopping all over the place. I have thought about getting some rare earth magnets to place between the crankshaft and the piston rods to hold them upright in one place, any ideas would be appreciated.
Tantanoola South Australia.
1979 KZ 650
1979 KZ 650
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- TexasKZ
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Re: Assembling the split cases
09 Oct 2026 07:36 - 09 Oct 2026 07:44
I am pretty sure the factory manual says to install the crankshaft assembly and the transmission assembly in the inverted upper case, then place the lower case with the shift shafts and forks on top of it all.
The procedure starts on page 84. www.kzrider.com/filebase-alias/send/15-k...-1977-service-manual
The procedure starts on page 84. www.kzrider.com/filebase-alias/send/15-k...-1977-service-manual
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD slowly moving toward resurrection
2000 ZRX1100 not ridden enough
www.kzrider.com/forum/11-projects/620336...amateur-build-thread
1981 KZ1000 LTD slowly moving toward resurrection
2000 ZRX1100 not ridden enough
www.kzrider.com/forum/11-projects/620336...amateur-build-thread
Last edit: 09 Oct 2026 07:44 by TexasKZ.
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- Vietvet
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Re: Assembling the split cases
09 Oct 2026 18:29
OK so I figured that a few years ago when I lost interest in the project I fitted the crankshaft to the bottom case along with the primary chain along with the secondary shaft. I removed the secondary shaft and put the crankshaft in the upper case and I will fitt them together when I get new oil seals for the shaft ends
Tantanoola South Australia.
1979 KZ 650
1979 KZ 650
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- Injected
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Re: Assembling the split cases
10 Oct 2026 06:02 - 10 Oct 2026 08:43Lining up the shift forks correctly is the hardest part especially when doing it alone, much easier when someone else helps hold the lower case half.
1978 KZ650B2 w 1197cc Z1 engine
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1978 KZ650C2 w 762cc DFI project
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1979 KZ650C3 w 831cc Hot Rod engine
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1977 KZ650C1 stock restoration project
1978 KZ650B2 modified project
Last edit: 10 Oct 2026 08:43 by Injected. Reason: more info
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- Vietvet
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Re: Assembling the split cases
10 Oct 2026 14:55
Yes another set of hands would be useful, I first did a dry run without the sealant and got the forks into the correct places then removed it applied the sealant and it went on first go.I gave myself a well done pat on the head. Only for a minute though because I was looking through the opening where the starter motor slots into and it was empty of anything to mesh with. Luckily I could remove the bottom sump, oil pump and secondary shaft and fit the pinion. It is all good and each time I pull things out and replace them it is getting quicker and easier.
Tantanoola South Australia.
1979 KZ 650
1979 KZ 650
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