Another basket case project, but with potentially a different end goal!

Great looking Paul! This makes the engine a modern look. Are you going to replace some cover bolts with stainless, or keep original and pain them grey? Either way, a different but equally good look in each own way. It's easy to play with it later, changing one bolt at a time. Count your blessings having a place to bake these parts!

Thank you for the chains photos. But I couldn't figure out the distance measurement between let's say 18 links. I have an old chain and I'd like to evaluate it based on comparison to a new one. A similar way as with the cam chain or timing chain for example - the cam chain 20 link service limit is 128. 9 mm, when pulled with a 5 kg force. Could you just give me those numbers for the brand new chains please?

No, the bolts on the engine case will be the same colour, but the bolts on the covers I'm thinking black. Colour scheme is now very likely to be chrome/silver, grey, black and gold exhaust and smaller accentuating elements.

What I as trying to imply was that the length difference was minimal. However, here is what I could measure using an ordinary(!) ruler:

Primary, 9 links, end-to-end 17cm exactly
Secondary, 10 links, end-to-end 18.9cm.

Hope that helps.

Paul

Great, thank you! It will give me an idea of what I have here before putting all back together.

Grrr!

Mechanical seal for water pump. Old one at the top, new one below.



Wrong size!

Note to self: measure and make sure before ordering!!

That's too bad Paul. Sorry to hear that.
Since you are a new face around here, you may not know my little secret about using www.Partzilla.com as a look up tool. Simple enough. Create an account and then use the site. You can find part numbers for all power sport vehicles there.
49063-1002 fits the following
Kawasaki Motorcycle 2000 KDX220R - KDX220-A7 Engine Cover(s)

Kawasaki Motorcycle 2000 KLX300R - KLX300-A5 Engine Cover(s)
Kawasaki Motorcycle 2000 KMX 125 - KMX125-A13 Engine Cover(s)
Kawasaki Motorcycle 2001 KLX300R - KLX300-A6 Engine Cover(s)
Kawasaki Motorcycle 2001 KDX220R - KDX220-A8 Engine Cover(s)
Kawasaki Motorcycle 1999 KDX200 - KDX200-H5 Engine Cover(s)
Kawasaki Motorcycle 1999 KLX300R - KLX300-A4 Engine Cover(s)
Kawasaki Motorcycle 1999 KMX 125 - KMX125-A12 Engine Cover(s)
Kawasaki Motorcycle 1999 KDX220R - KDX220-A6 Engine Cover(s
Kawasaki Motorcycle 1995 KLX250R - KLX250-D3 Engine Cover(s)
Kawasaki Motorcycle 1995 KDX200 - KDX200-H1 Engine Cover(s)
Kawasaki Motorcycle 1996 KDX200 - KDX200-H2 Engine Cover(s)
Kawasaki Motorcycle 1996 KLX250R - KLX250-D4 Engine Cover(s)
Kawasaki Motorcycle 1998 KLX300R - KLX300-A3 Engine Cover(s)
Kawasaki Motorcycle 1998 KDX200 - KDX200-H4 Engine Cover(s)
Kawasaki Motorcycle 1998 KDX220R - KDX220-A5 Engine Cover(s)
Kawasaki Motorcycle 1997 KLX300R - KLX300-A2 Engine Cover(s)
Kawasaki Motorcycle 1997 KDX220R - KDX220-A4 Engine Cover(s)
Kawasaki Motorcycle 1997 KDX200 - KDX200-H3 Engine Cover(s)
Kawasaki Motorcycle 2002 KDX220R - KDX220-A9 Engine Cover(s)
Kawasaki Motorcycle 1994 KLX250R - KLX250-D2 Engine Cover(s)
Kawasaki Motorcycle 1998 Ninja ZX-9R - ZX900-C1 OIL PUMP - OIL FILTER
Kawasaki Motorcycle 1998 Ninja ZX-6R - ZX600-G1 OIL PUMP - OIL FILTER
Kawasaki Motorcycle 1999 Ninja ZX-9R - ZX900-C2 OIL PUMP - OIL FILTER
Kawasaki Motorcycle 1999 Ninja ZX-6R - ZX600-G2 OIL PUMP - OIL FILTER
Kawasaki Motorcycle 2000 Ninja ZX-12R - ZX1200-A1 OIL PUMP - OIL FILTER
Kawasaki Motorcycle 1997 Ninja ZX-6R - ZX600-F3 OIL PUMP - OIL FILTER
Kawasaki Motorcycle 1996 Ninja ZX-6R - ZX600-F2 OIL PUMP - OIL FILTER
Kawasaki Motorcycle 1995 Ninja ZX-6R - ZX600-F1 OIL PUMP - OIL FILTER
Kawasaki ATV 2002 Prairie 650 4X4 - KVF650-A1 RADIATOR
Kawasaki ATV 2001 Prairie 400 4X4 - KVF400-C3 RADIATOR
Kawasaki ATV 2002 Prairie 400 4X4 - KVF400-C4 RADIATOR
Kawasaki ATV 2002 Prairie 400 - KVF400-D4 RADIATOR
Kawasaki ATV 1999 Prairie 400 - KVF400-D1 RADIATOR
Kawasaki ATV 2000 Prairie 400 - KVF400-D2 RADIATOR
Kawasaki ATV 2001 Prairie 400 - KVF400-D3 RADIATOR
Kawasaki ATV 2000 Prairie 400 4X4 - KVF400-C2 RADIATOR
Kawasaki ATV 1999 Prairie 400 4X4 - KVF400-C1 RADIATOR
Kawasaki ATV 1997 Prairie 400 4X4 - KVF400-A1 RADIATOR (-VF400AE515522)
Kawasaki ATV 1998 Prairie 400 4X4 - KVF400-A2 RADIATOR (-VF400AE515522)
Kawasaki ATV 1998 Prairie 400 - KVF400-B1 RADIATOR (-VF400AE520627
Kawasaki ATV 1998 Prairie 400 4X4 - KVF400-A2 RADIATOR (VF400AE515523-)
Kawasaki ATV 1998 Prairie 400 - KVF400-B1 RADIATOR (VF400AE520628-)

49063-1001 fits the following

Kawasaki Motorcycle 1983 Voyager - ZN1300-A1 Water Pump
Kawasaki Motorcycle 1982 KZ1300-A4 Water Pump
Kawasaki Motorcycle 1981 KZ1300-A3 Water Pump
Kawasaki Motorcycle 1980 KZ1300-B2 Water Pump
Kawasaki Motorcycle 1980 KZ1300-A2 Water Pump
Kawasaki Motorcycle 1979 KZ1300-A1 Water Pump
Kawasaki Motorcycle 1986 Voyager - ZN1300-A4 Water Pump
Kawasaki Motorcycle 1985 Voyager - ZN1300-A3 Water Pump
Kawasaki Motorcycle 1987 Voyager - ZN1300-A5 Water Pump
Kawasaki Motorcycle 1988 Voyager - ZN1300-A6 Water Pump
Kawasaki Motorcycle 1984 Voyager - ZN1300-A2 Water Pump

it took me 5 times longer to cut and paste this info than it did to look up and figure out why the seal was the wrong size. I just think this tool is great for figuring out what parts are transferable between the ZN and the Z and the KZ 1300's In this case, I figured out what that part actually fits. Maybe you can advertise the on a local site and recuperate some of your costs.

A word of caution though. I have tried twice to order parts from them that their inventory says is available and the costs were charged to my PayPal account only to find that they didn't have the part and I had to ask for my refund. Otherwise the refund was not forthcoming

I'd suggest to stay with genuine Kawasaki parts when it comes to crucial components, unless proven good quality aftermarket. I got my mechanical seal from Kawasaki dealership - they actually had it. Also, when the time comes, although expensive - I'd get a genuine Kawasaki head gasket. At least here in Canada they have it.