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Note to myself: current shim sizes. None of the original valves or seats had been ground.

You asked yesterday about a supplier for shims. Z1 Enterprises has a full range. Ther're great to deal with.

www.z1enterprises.com/engine-parts/shims/29mm-shims.html

Thanks Kawboy!

Today I sorted out the water pump assembly. The oil seal, the mechanical seal and the 0-ring are all new.



I applied a very thin layer of liquid gasket to all surfaces of the seals and any others where tightness is required. Just a thin lick also when assembling everything into the block.



I applied assembly lube by Lucas to moving surfaces and tightened the nuts to 14.5 ft./lb. As per the manual, only fixed 12 mm wrench should be used on the shafts. The nuts are a 12 mm socket on a torque wrench.



Water pump impeller secured in the block with a 11 mm circlip.

I had several piston rings dead stuck in the pistons. Simply fused, just like they were in the cylinders. I cleaned them in my ultrasonic cleaner and all sooner or later just popped out. Fantastic!

I used a 1 to about 4 Simple Green HD (purple color) to distilled water solution, set the temperature to 55 degrees Celsius. Cleaning pistons took 15 minutes. The worst one took 40 minutes to have the rings loose. Now all look like new

The piston rings are aftermarket from the UK. 62 mm. I checked the clearances in the cylinders and they are all fine.



The cylinder block all set except for painting if flat black. Next thing will be masking it with a tape and painting with high heat resistance spray paint.



The cylinder head cover already assembled and painted. New stainless steel bolts all in place. I will be applying anti seize compound when tightening them when the time comes. All the original bolts got cleaned in the ultrasonic cleaner in the meantime. All perfect and shiny. A perfect backup.

I use Kendal cleaner model HB-S-821DHT. Frequency 42 KHz, Ultrasonic power 480 W, Heating power 500 W.
It's fantastic. I can submerge a whole carburetor in it. The KZ 6 block is just one cylinder too big for total cleaning, but plenty of depth to do it one side at a time.
Anything four or two cylinder would fit in nicely. I will work great on any cleaning on my other two bikes.