1981 KZ550A2 Update

So what's the technique here folks. Everything will be clean and knock pins clearly checked out. Do I apply to top case and let set before joining bottom case or get a bead on top and plan to join as soon after applied before cure? Also what size bead is enough? I am aware of warning to not over do it. Using Yamabond 4, can't find 1194 local here. R

Just a light coat and put it together immediately.
Steve

So, remaining parts are due today, my goal is to get the case halves back together at a minimum. Last night I went through upper and lower cases for final cleaning and oil passage blow out. Put the rods back on with fresh assembly lube and cleaned the case bolts and hit the threads with a die to clean well. It sure looked like there was ant seize on all bolts. White greasy film present. Bolts are in good nick. Will fire up the video as i start tonight. Some pics will get here and the full riveting Oscar worthy video will hit utube after compiling. R

Well I wish I could say it went great, and it mostly did. Can u see what's wrong in this pis that I found in post production?

Will be starting over tomorrow. :sick:

Shift drum issue?? What happened?

Broken bolt.
Steve

Look again, I would not have noticed without video that I forgot to seal the inner crank mating surfaces. It would have gushed oil and burned up. Got it back together with an even better amount of sealant. I used way too much on the first shot. God treats some people special and makes things happen over and over til I get it right. :lol: I know how to fit 550 cases now !. R

Isn't there a cover there?
Steve

No they press together with case bolts running through, no cover. I thought of every way to avoid a redo, but oil would have come out the bottom running along the unsealed 10mm case bolts. The area is clearly marked in the manual for sealer. Took the dy off back at it soon. :silly: R

We've all done one time or another. Good thing you caught it.
Steve

Noticed the excess sealer, but not the missing sealer. Good pickup.

I use an acid brush to dab and spread out the sealer. All you need is a thin coat.

The red grease on the transmission bearing saddles is not necessary. Don't think it will hurt anything though.

Well, mission accomplished. She is rebuilt. Everything went back together as is should by the manual. Valve clearances all check in range, but on the low end they will need to be checked again this year. Having a buddy help me put it in the frame later today, so it will get in not sure if it'll get started today. There is still a bit if installing frame parts wiring etc. Been at it all day. Lotsa pics and video to come. R