Removing 620 Kawasaki Crankcase Cover

[king gill]

I have 95 a conquest..Not positive on the year but for some reason Im thinkin 95'...FD 620 Kawasaki.....The Gasket on what i guess is the crankcase cover was leaking antifreeze...had to remove clutch...got that off...Now I cant get the crank case cover off....seems like something is hangin up...got it about 1/2 inch or so away from the block..but thats it... What am I missing???????mechanically Im new to these machines...

Guess I should of just smeared some mega Black on it to plug up the leak but I wanted to fix it right...so here I am ...1 month before icefishin and my machine is down and out...I need some Help please!!!!!!!

[LarryW]

I have not Idea with that engine but you can maybe search for lawnmower or kawasaki mules forums or something maybe for engine problems.
Sorry no body has helped yet.

[Rock Doctor]

Pics???

I'm not a great small engine guy, but might be able to help if I could see what you are doing.
On the other hand, if you set a Turbine, Jet Engine in front of me, I could probably rebuild it for you in a couple days

RD

[farmtoybuilder]

Here's link to Kawasaki engines. Cover should pull right off! It could be sticking on crankshaft bushing or cam is sticking to cover? Tap around it with rubber mallet. PM me if you have any questions.

http://kmcb2c.econnect.partsandwarranty.com/kmcb2c/Menu?action=CATALOGB2B&prodID=3189651&elementType=2&historyDepth=2&CHANGENUMBEROFITEMS=63

Kawasaki Engines and Power Products - Engines - FD620D

[Roger S]

If the cam spins in the cover, need to back off/ remove pushrods 'cause it's pushing down on the cam.

[king gill]

HMMMM ok guys thanks....I'll go battle with it some more and maybe take a pic or 2 so you know what Im talkin about..cause really i dont

[racerone3]

If the cam spins in the cover, need to back off/ remove pushrods 'cause it's pushing down on the cam.

that should only be an issue when one of the valves is open. on compression and power strokes with both valves closed there should be very little pressure on the cam shaft. try spinning the crank 1 full revolution and see if that helps

[Roger S]

All 4 lifters on the base circle at once on a v twin? I think he has his hands full trying to r&r that cover while the engine's installed as it is, without backing off the valve train. He can pop it off, but re assy will be the hard part.

[racerone3]

right you are Roger. i've been working on single cylinder engines all week and they have me in the wrong frame of mind. diregard my previous statement

[king gill]

DOH !!!!!!You tellin me now I gotta pull the motor just to change a gasket....not cool...the only thing I see attached to the cover is a plastic gearThis is on the clutch side of the motor...like I said ive never tore into one of these B4 so I appreciate all your help..its hard to explain correctly I guess.....aint gonna get to much time to work on it this week....Gramps passed away last night....man I hate Funerals

[king gill]

IM WRONG!!!!!!!!There is another gear down there..just cant see I guess..I can move the cover back and forth easily just cant get it to go any farther than a 1 inch or so...I know pics suck....Looks like I would be best to pull the motor eh....What did I get myself into...lol

[Roger S]

Would be best to have it out on the bench, so you can see in there, esp during re assy. (I'm guessing, never had one apart)>> That top gear and shaft is the cam, the plastic one on the bottom is the oil pump, and will come off with the cover. It not wanting to come apart any further may be the rust and dirt on the crankshaft preventing it from sliding through the main bearing in the cover. Push the cover back on and clean up the shaft. Or pull the engine. Keep that cam gear/shaft pushed inside when you remove the cover. The cam gear and crank gear have to line up with specific marks.

If in doubt, take it to a mechanic.

Sorry about Grand Dad.

[king gill]

Thank you for your advice!!!!I would like to try and fix it ... looks like I will be buying myself some Repair Manuals...The only way to learn is do it myself..Im sure if I take my time I should be able to handle it....So pullin the motor it is...DAMN!!!!!!!!!When I get started I will try and post my progress...This shall be interesting......

[spits]

Is there a bearing on that end? If so ,you could be hanging up on the bearing. sometimes the bearing will slide off a bit then gets hung up on the shaft. Try heating the case with a heat gun(a.k.a. a paint stripper). The aluminum case heats before the bearing and releases the bearing. If that is the problem, tapping the case with a soft face hammer after it is too hot to touch, should dislodge the case.

[king gill]

Yea Im sure theres gotta be a Bearing there..I bet thats it...DUH..why didnt I think of that...anyhow I think Im still gonna yank the motor...then since the motor is out...i'll be like see honey I might as well go and buy the winch kit now that I have room to install it Im always thinkin...lol