KZ650 cafe-racer. Engine assembling. Part 6.

With the starter clutch repacked there was nothing to stop me from finishing the Kawasaki KZ650 engine assembling. Workbench  was ready for another (mostly final)  stage of the process.

Kawasaki KZ650 engine assemblingTo drive the secondary shaft in place I used an improvised driver: a piece of aluminum pipe of suitable diameter plugged with aluminum blank. Since not only the cylinder head, but also camshafts were installed beforehand, I had to work on the secondary shaft and other engine bottom components with the engine positioned a bit weirdly.

Kawasaki KZ650 secondary shaft installation Kawasaki KZ650 secondary shaft installationAs soon as the secondary shaft was installed, I prepared the oil pump.

Kawasaki KZ650 oil pump installationTo mount the oil pump and the secondary shaft stopper plate I used countersunk Allen bolts.

Kawasaki KZ650 secondary shaft installation Kawasaki KZ650 oil pump installation Kawasaki KZ650 engine assemblingOil pump was followed by the oil pan (along with a new genuine gasket, O-Rings and bolts).

Kawasaki KZ650 oil pan installation Kawasaki KZ650 oil pan installation Kawasaki KZ650 oil pan installationPlease pay attention  to the oil pan’  bolts. It’s the first time I with my attention to details went so far as choosing even engine bolts  in various finishes: chrome plated for polished covers, matt zinc plated for painted parts, and gloss zinc plated for semi-polished oil pan.

Kawasaki KZ650 oil pan installationI staked heads of all countersunk bolts and set the engine into a “more natural” position.

Kawasaki KZ650 engine assemblingThen it was time to put back the secondary shaft gear. For this purpose I used another piece of aluminum tube, a couple of washers and a bolt.

Kawasaki KZ650 secondary shaft gear Kawasaki KZ650 secondary shaft gearAfter this I turned my attention to clutch components.

Kawasaki KZ650 clutch installation Kawasaki KZ650 clutch installationI was glad that Oksana was in the workshop at that time: with 130 Nm of torque for the clutch nut it’s better to have a pair of spare hands to keep the clutch holding tool in place when torquing the nut.

Kawasaki KZ650 clutch hub holder Kawasaki KZ650 clutch hub holder Kawasaki KZ650 clutch hub nutNext were clutch plates.  I unpacked and oiled new genuine friction plates. Metal plates were stored oiled, therefore they were ready to put in place.

Kawasaki KZ650 friction clutch plates Kawasaki KZ650 friction clutch platesSoon the clutch was packed with plates. I installed a PMC clutch pusher.

Kawasaki KZ650 clutch pusher Kawasaki KZ650 clutch pusher Kawasaki KZ650 clutch pusherAnd TRW reinforced clutch springs.

Kawasaki KZ650 clutch springs

Clutch was ready.

Kawasaki KZ650 clutch assembling Kawasaki KZ650 clutch assemblingThen I installed the starter motor and secondary shaft cover.

Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assembling Kawasaki KZ650 engine assemblingAnd at last it was time to use my new rotor holder for the first time.

Kawasaki KZ650 alternator rotor holder Kawasaki KZ650 alternator rotor holderAnd at this point I interrupt my narration once more. It seems that the next part  will be the final chapter of the Kawasaki KZ650  assembling story.

So, to be continued.

 

Facebooktwitterredditpinterestlinkedinmailby feather

Leave a Comment

Your email address will not be published.