KZ650 cafe-racer. Engine assembling. Part 4.

With piston bases and piston ring compressors it was a matter of minutes to get cylinders installed. I spent more time on photo shooting than on installation itself.

Kawasaki KZ650: cylinders installation Kawasaki KZ650: cylinders installationI oiled bores because I could not exactly foresee how long the engine will sit on my table before it starts for the first time.

Kawasaki KZ650: engine assemblingEngine with cylinders installed looked inspiring.

Kawasaki KZ650: engine assembling Kawasaki KZ650: cylinders installationI installed new genuine dowel pins, O-rings and the latest version of oil restrictors (early KZ650 wasn’t equipped with them, but I picked KZ650 cylinders that for sure were compatible with restrictors).

Kawasaki KZ650: engine assembling Kawasaki KZ650: engine assemblingNext went components for the timing chain’ tension system. I oiled them and assembled…

  Kawasaki KZ650: components of timing chain' tension system Kawasaki KZ650: components of timing chain' tension system

… then I installed them in place along with new rubber dampers (shafts and rubbers are all OEM or genuine, whatever is the best word for original parts). As the last “brushstroke” before cylinder head could be put in place was installation of a new genuine cylinder head gasket.

Kawasaki KZ650: components of timing chain' tension system Kawasaki KZ650: components of timing chain' tension system Kawasaki KZ650: components of timing chain' tension system Kawasaki KZ650: components of timing chain' tension system Kawasaki KZ650: engine assemblingWith preparations completed it was time to take from the bags all new (and again, genuine) cylinder head nuts and washers:

Kawasaki KZ650: cylinder head nuts and washers Kawasaki KZ650: cylinder head nuts Kawasaki KZ650: cylinder head nutsAs well as cylinder head bolts along with custom made adapters:

Kawasaki KZ650: cylinder head boltsAnd since the KZ750 cylinder head itself was already assembled…

Kawasaki KZ650: KZ750 cylinder headAnd again, it was a matter of minutes to install the cylinder head and torque all nuts and bolts ¬†according to specs. Kawasaki books don’t state using oil on threads and flanges and threads of cylinder head nuts. However, I have read service manuals of different manufacturers and I always apply a smear of oil on both thread and flange of cylinder head nut. A little oil allows for tightening cylinder head nuts more evenly.

Kawasaki KZ650: engine assembling Kawasaki KZ650: engine assembling Kawasaki KZ650: engine assembling Kawasaki KZ650: engine assemblingWith the cylinder head installed, the engine looked mostly assembled, but still there was a lot of work to do, so the story is still far from being finished.

Therefore: to be continued.

 

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