1981 KZ550A2 Update

Vapor blasting seems to be a UK thing. There are places that do it in the US but it's not common. Sure does leave a right fine finish I'd say. Too bad it's not more common in the states.

Regarding the secondary shaft, I struggled with that when doing my 750. If you remove/install the bearing while on the shaft you will have to pound it in place by effectively driving it from the inner race. Not the recommend practice. I drove the bearing out with the shaft and then replaced it. During install I tapped it in place from the outer race. Another thing is to check the rubber dampers on the cush hub. There was a lot of play in those dampers on my bike despite it being low mileage. You might want to check that out carefully and replace the dampers if there is noticeable play.

Here are a few pics. I have the gaskets cleaned up and pretty ready for reassembly. Every thing will get a final clean and assembly lube as it goes. Need a few more parts in the mail

The first couple of pics show the main crankcase seal journals. The ignition side was pretty rusted even int the seal area. I clean out as gently as possible and will watch closely how seals mate up.

Now that I have looked at the paint close up I think I'll skip the strip and repaint. Gonna keep the patina.

R

Bearings look good. New valve guide seals and rings?
Steve

Valve guide seals yes, rings no. Will lap the valves too. At 3500 miles and everything mics well I will clean carbon off the pistons and use em again. What do you make of that crank oil seal area?The rust was to the second seal lip on the ignition side. The crank end was not scored and I cleaned it and the groove well. Hopefully it will hold oil with a new seal.

Get some three bond, Yama bond or the like. I'm not concerned with it sealing in the cases. What about that damper/spacer?
Steve

Which part? not sure I saw a dampener. R

Behind the alternator rotor.
Steve

Oh, it's still on the crank. Puller bolt is coming in a couple days. I thought my hardware store might have the 18mm 1.5 pict bolt, but they only had coarse thread in 18mm. There is a seal there too, not sure if there is a dampener under it or not. R

I don't think it's a seal.
Steve

Threebond 1184 is a good choice for between the case halfs.

Oh, and hope you are using OEM Kawasaki seals and gaskets where ever possible.

It the same seal type as the ignition side, but a bit smaller, on the 550. R

Yep, kaw stuff from partzilla. While I don't mind subbing orings, other parts are engineered best by Kawasaki. Some of the bottom end things are a bit oddball - beveled orings and the like. R