KZ650 Sleeper Build (KZ1000 engine transplant)

One of the few places where plenty of RTV is your friend...

wrote:

One of the few places where plenty of RTV is your friend...



 

Yeah, I don't have too much use for RTV on engines but according to my local Z1 guru there is going to be more required on this build.

The barrels are bored out so much that there is not much left around those black sound deadening plugs at the base gasket. Apparently that is a potential leak path that requires some RTV on a 1200 build. Some RTV is also required on the top of the barrel in that O ring groove around the cam chain tunnel. That groove will get filled with RTV then cut flush with a razor blade. The stock O ring while fresh sits up way too high and will no longer fit because of the bigger OD liner flanges.

All areas on the 650/750 I never have to worry about!

I fabricated new rubber barrel hole plugs from the scrap material I cut clutch pucks from. The old ones were rock hard so it would have been worse working with them. The new ones are a super tight fit. I need to get the barrel prepped and those plugs reinstalled.

Here is the difference in a stock 1015 barrel and mine bored to 1200 :





O ring groove :



I am hoping I can get the top end installed early next week. We have a bunch of family stuff going on, and I need to be cautious on how much time I spend on this as I don't want to end up sleeping in the shed

I just ordered a new 530 O ring chain, the shortest one at a decent price was 110 link so I will need to cut it to fit.

The one on there now is sitting way back in the swing arm slot, and I don't want to have to cut it since it fits a 650 and only has about 300 miles on it. I was thinking this engine is going to stretch out chains so might as well start with one closer to the front of the adjustment slot.