Rebuild kit for KZ650 B- How to take apart?

:huh:

Thank you in advance for any help you can offer. I purchased a rebuild kit for my KZ650 1978 and I am taking it apart when I see that I have a new diaphram, but I can't seem to figure out how to get this square plastic thing out of the old piece and how to add it in between the new diaphram. the kit also came with two o rings that I do not see in the original petcock. Could these be for other models and just not needed for my bike? It is a 78 KZ650 B that I am almost done bringing back from the grave.

Any help is appreciated.

Thank you,

Pnedac

By the way the piece that I was referring to is the Nylon Spacer that sits between the diaphragm that I cannot see how to get out from between the old one and I also can't see how to get it into the new one.

I think if I can figure one of these out then the other will tell the story.

Any help is appreciated.

Thank you,

What rebuild kit? For the petcock? If so, you kinda have to fold & pull off the old diaphragm thru the hole in the middle of that square plastic spacer, then fold & push the new diaphragm in place, again thru the hole. It's been a while, but I think the diaphragm can only go thru one way. As for the o-rings, one may be for the tap lever (some models may not use that o-ring). I think the larger o-ring is for the petcock where it contacts the tank - it fits into the groove of the petcock body.

Here is a link to the petcock rebuild kit that I have:

www.z1enterprises.com/ItemDetails.aspx?i...um%29&item=KL18-2699

I just could not see how the spacer can be removed without breaking something which is what I would like very much to avoid. I will take your advice and see if I can make something happen. Also thank you for the note about the o rings. I couldn't see that they belong to this petcock, but I know that sometimes they cover a number of models.

Cheers,

In the Z1Ent link you can see the diaphragm o-ring side. You have to push that thru the plastic spacer. The other side has the large disk for the spring & I don't think it will fit thru the hole as easily. If you do an internet image search for petcock diaphragm, you might find some photos of the spacer n stuff.

Here are the instructions from the Kawasaki Service Manual and the diagram from Kawasaki.com. Ed

Thank you 650ed for posting this. Very helpful. The issue is not so much in how to assemble, but how to get the nylon spacer out of the old diaphragm and into the new one without breaking anything. I will be home soon and look this over again, but it did not appear that there was a viable way to get it off without some trouble. I wlll post a picture of my issue too in a bit here.

Thanks!

There's nothing to it really. The old diaphragm may be stuck to the nylon spacer, but that's no big deal.

The old rubber part of the diaphragm was stuck to the nylon spacer, but that is not the problem. The nylon spacer is "locked" in because there is no mechanism to get it out from either side of the unit. On the one side is the large disc and on the other side there is a outer lip that is larger than the spacer, again making it so that it won't come out. These pieces don't seem to screw apart or anything so I am feeling pretty stuck on this.

..

I notice that the site that I got the kit from has a note that says "Vacuum Diaphragm requires (where applicable) the nylon spacer from the diaphragm being replaced." I can see with the new diaphragm that there is a space in there for the nylon spacer, but for the life of me I can't figure out how to get it in there. Somebody make me feel stupid! I welcome it.

Does the diaphragm plunger move? ... the deal in the center. Have you got any other pics of the petcock? My guess is that you may have to get a replacement petcock. Z1Enterprises sells an aftermarket Suzuki vacuum petcock that should fit your tank.

Try doing a google image search for 1978 KZ650 petcock diaphragm to see if anything looks familiar. Here's a topic - I think you have to log-in to see the photos. KZ650.Info - Petcock rebuilding