Cool, thanks Adnoh!
I assembled the
motor ((
Internal Combustion Engine ? )), and I air leak tested it.The jug is leaking all over the place-front, rear,everywhere! I went into CSI mode-
1-is the head bad?
2-is the cases flat?
3-gaskets wrong, measurements?
4-mabye I just torqued the bolts wrong amount?
5-need more brains?
I first checked the head.Now on these Kawasaki jugs I send them to a company called US CHROME in WIsconsin. When they re-plate them, they sell you a 70mm Wiseco piston kit and they set the ring gaps and piston wall clearances with the piston you get-I called them and checked to see if when a client sends them a jug they check it for see the mating surfaces are flat.I could not speak to a tech as they were busy, but was informed the do prior to re-plating. So, if this is true then that rules out the jug being warped.
Gaskets-I had 3 gasket seats sets here.MOOSE-VESRAH and OEM. I measured all of the base jug gaskets.All were .02mm which was amazing to me as I measured the other gaskets in the seats and there was varying sizes per each gasket.HMMM. I did try to use all 3 gaskets on the jug,each time it leaked in the same areas.I then tryed to use Hondabond on the lower surface(case side) and torqued, leaked still.So I have to go on with the CSI.
Torque values was 25 ft per manual.I double checked them, replacd the batteries even in my wrench, it is 25 ft pounds with my 2nd wrench.
Need more brains-100% CORRECT!
Now we come to the cases.A quick look at them it appears they sit flat.I had to use 2 different case halves on this motor (( Internal Combustion Engine ? )) due to damage on 1 of them.I have a 85 motor (( Internal Combustion Engine ? )), the case halves are supposed to be the same tolerances between 84 motors and 85 motors,there is no written documentation I can find to say otherwise, manual does not state not to use them together-or any tolerance issues if doing so.I took the jug off, and visually ran a razor balde on the right side case going toward the left side.When it came to where the cases mate, it stopped.OH OH.
WTF? I ran the razor blade the opposite way from left to right-it dropped down to the right case where they meet.So I can assume the cases are not mated properly.Now why?
I installed new dowels in the cases prior to mating them.I inspected each and every hole to make sure there was no ob longing in the holes especially where the dowel pins are, which were all fine.Did I mic them-no.Can should I? mabye I should now.I'll check the manual and see if they even list a tolerance.I lapped the cases and checked with feeler guage and straight edge on all the surfaces prior to mating-they all were flat.
What I think I did wrong was I should have mated the cases toghether and lapped them at the jug surface without the internals in there.It appears to be a issue with the cases at this stage.I am going to take the motor (( Internal Combustion Engine ? )) apart again, and check the surfaces with a straight edge at the base of the jug.I will lap them together without the internals in thereto see if indeed they are not flat and not perfectly matched.