KZ650 Top end O-rings

Hi there, 

I am piecing together a kz650 which top end was stripped. I got it all together using the service manual, then found a bag of used orings with the parts I got for the bike. This makes me nervous I missed them. I know I put the two oval and two round o rings on the right in for the oil passages through the cylinders and head. The other o-rings I have no idea where they may be for and I can’t find a list or anything in the manual. Does anyone know where these may be from? 

Looks like you got the ones on the ends of the top case, just before the cylinders go on.  The ovalish ones go on top of the cylinders on each end.  I can't tell where the other ones go.

 

 
 

Can’t help with the ORings. I’m concerned about the cam chain gears. The rear has the axle upside down with the rubber damper blocks underneath it. Also what is the washer I see next to the gear. No washer need to be there.

 

Hey Mikaw. Appreciate any help. I had the cam gears with the curved shaft side down and the isolation blocks on the top side for both. The front blocks are under the gasket and the rear blocks I stuck to the bottom side of the head with a dab of glue before installing the head. Is this not correct? Also is the washer you are talking about possibly the swinging roller (12) for the chain tensioner which hinges on the rear gear shaft? Thanks! 

Mikaw, zoom in on op picture. The rubbers are not fitted yet. You can see the flats they sit on. 

Your good. And yes I see the yellow chromate color on the “swing” gear. That’s the tension adjuster. In the first photo it looked like a silver washer. 

Warren3200gt wrote:

Mikaw, zoom in on op picture. The rubbers are not fitted yet. You can see the flats they sit on. 

Yes, I do. Thank you.

Hey Warren, only o-rings I can see that I don’t remember putting in are the qty(2) of #4 on the crankcase. Are these supposed to be over the right-Center studs? Big concern if these were missed? 

Orings on the studs or lack of doesn't matter. Oring between the cylinder and case on each side matters, as well as the oval ones between the cylinder and cylinder head. That's it for Oring problems on the block/cylinder/head, but there are 50 more Orings throughout the engine that all go bad and leak. I like the 650, and probably have ridden 650s more than most, but what an annoying design using all the rubber Orings that harden and leak. The Z1/KZ1000 doesn't leak, or at least far less commonly. 650s leak if ridden much. The heat hardens the Orings and leaks will be a regular thing that will be annoying as I said already.

sflesch94 wrote:

Hey Warren, only o-rings I can see that I don’t remember putting in are the qty(2) of #4 on the crankcase. Are these supposed to be over the right-Center studs? Big concern if these were missed? 

Not the end of the world to have missed those two. They fit on the right central pair of studs. The stud threads in the case on those two are open and go all the way through to the crankshaft chamber. The rest are blind. 
The thinking was that the o rings would stop oil seeping up those two studs and leaking out. I've never known a 650 to leak there. 
Ron Kz650, the only place I've seen leaks on 650s is from seals not o rings except the rev counter drive. 
Very occasionally the leak from the clutch pushrod and front sprocket seals but that's not surprising with all the grease and rubbish from the chain that accumulates and collects in there.