1980 KZ1000E ST project

Do the front studs get orings and the back get sealant? Or is sealant and orings used on the back studs only?

R

That I can't tell you. I'd guess they all get sealant but I don't think there's room for O rings on the front ones.
Steve

There were no orings on any of the studs on disassembly. I am sure someone knows. From the manual it looks like the rear studs get sealan and the fronts get orings. R

Okay, so I still need some assistance.

I think the cylinder base orings (4) in the manual are meant for the cylinder sleeves below the block. My question is do I need em. This is a MKII motor. There were not any on them upon disassembly. All of the parts fisches for 80 KZ1000E2 do not show the cylinder base orings as a part. The FSM says put four new orings on the cylinder bases. What says ye?

Also the FSM says sealant on the case where the four studs on the rear of cylinders 2 and 3. Seal em all or just the four?

I know it seems counter intuitive to not do what the manual says, but looking for someone who knows. R

Paint that is

It came out acceptable to me. Should have degreased the head one more time, but got impatient. Most of it will be covered by my shiny valve cover in previous pics. Sealant on the four studs in back #2 and #3 per manual. Waiting for 2mm x 73mm orings to arrive for cylinder bases. Head is painted and drying. More to come. R

R

You were talking about the large O rings around the sleeves? The 903's had them but the 1015's didn't. I don't have them in mine. They really didn't do anything in the 903's anyway.
Steve

Hi Steve, yes the Kaw ST manual says 4 orings for cylinder bases. Oddly enough, there were not any in it. Would you put them in? Also I got a single cam bearing and mic'ed it against the old one that is cracked. They are the same thickness to .00mm . I am gonna put the new in and see how that goes. I can't put a cracked one back and the others look fine. More to come. R

Don't bother with the O rings just use a good base gasket.
Steve

Another obscure question. On disassembly, the knock pins for the case came out in the bottom of the block and and knock pins for the block came out in the bottom of the head. Do I need to pull these and put them in their places? Or just bolt em back up. I am thinking base and head gasket alignment will be better with the pins the other sides. The problem is they are quite stuck to where they are, I didn't want to damage them. R

Another. Base gasket dry or greased? Also some have said to seal all stud at the case, manual says back 4 on #2 and #3. I did the front on #2 and #3 too, but not sure about sealant where the oil comes thru to the head or where the knock pins set? R

Leave the pins where they are if you can't get them out easily. They have a bevel on one side and the PO may have put them in wrong. I didn't use sealant on my base gasket. I bought it from a seller listed in my good guys thread. The gasket is nice and thick. It's the second one I bought from him. I get all my gaskets from him except the head gasket. I use a one piece for that. It wouldn't hurt to seal around the four outside studs. That's where the oil feeds are.
I use a one piece so I won't have a leak at the large O ring around the cam chain tunnel. I hate that and no matter what I buy, it always leaks there eventually. NOS is JUNK. It's been a year and no leaks.
Steve

This base gasket looks high quality. Not as thick as a point cover gasket but thicker than the valve cover gasket. I have the two piece head gasket and oring jobber. Will see how well it seals in, but I was aware that is the leak area on these bikes. Any way I guess I will skip the cylinder base orings and seal the rest of the studs and get things back together tonight. The head paint came out decent. Once i have the engine out of the stand there will be some final masking and touch up painting, but it sure is gonna look nice. Thanks for your help. R