KZ650 cafe-racer. Engine assembling. Part 2.

Next step in Kawasaki KZ650 engine assembling was connecting rod installation. As usual, I applied  mix of engine oil and Liqui Moly LM48 molybdenum grease to connecting rod bearing inserts.

Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assemblingI tightened connecting rods’ nuts with the crankshaft installed in the upper half of cases. Then I returned the assembled crankshaft with conrods on the shelf for a short time.

Kawasaki KZ650 engine assemblingSo I could Install all necessary parts into the upper half of the crankcase. Like new knock (dowel) pins:

Kawasaki KZ650 engine assemblingOr new rubber plug for oil channel:

Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assemblingOr starter motor idle gear:

Kawasaki KZ650 engine assemblingAfter this I prepared new crankshaft oil seals.

Kawasaki KZ650 engine assemblingAnd put  primary and timing chains on the crankshaft.

Kawasaki KZ650 engine assemblingAfter this  I greased crankshaft  bearing inserts with a mix of molybdenum grease and engine oil and installed the crankshaft into its place. In this way the upper half of the crankcase was mostly ready for assembling.

Kawasaki KZ650 engine assemblingMeanwhile I proceeded to lower half of the engine case. First I had to install a kickstarter mechanism. There are three retaining rings (circlips) to be installed on the kickstarter shaft. They all may look identical,  but in fact only two of them are identical. Third  retaining ring size is slightly different, so mind not to mix those rings up.

Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assemblingWith the kickstarter mechanism correctly assembled and in its place my next step was assembling the gear shift mechanism. I did it by the book using a new lock washer  for shift drum guide bolt and cotter  pin for 3rd gear shift fork.

Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assemblingI used the return spring bolt of the new design. It came with factory applied thread locking agent and some kind of coating on the part which is in contact with spring.

Kawasaki KZ650 engine assemblingWith all components in place I just checked gearbox fitment:

Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assemblingAnd then installed the transmission in the upper half of the crankcase. Both halves of the engine case were ready to be joined…

Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assembling

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