Tusk top end gasket kit

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CodyShires
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Tusk top end gasket kit

Post by CodyShires »

Hello all, just got my top end kit along with piston, wrist pin, etc. in the tusk kit there are two tiny o rings. What are they for?
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Re: Tusk top end gasket kit

Post by KDXGarage »

Did you look on the Kawasaki parts diagram to see if they matched up to anything OEM?
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Tusk top end gasket kit

Post by cornishwrecker220 »

I'm not sure but I think the tiny O rings you describe are for the powervalve operating rod that goes through the cylinder ...on each rod are 2 small grooves that seat these o rings .i think it's to prevent blow back from the exhaust gasses.
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Re: Tusk top end gasket kit

Post by John_S »

There is a main KIPS shaft that runs through the front of the cylinder from side to side. These are the seals you're pulling that shaft through when you remove it. One on each side of the cylinder.
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Tusk top end gasket kit

Post by John_S »

Here they are (92049)
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CodyShires
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Tusk top end gasket kit

Post by CodyShires »

Oh there they are thanks for the help!
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Julien D
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Re: Tusk top end gasket kit

Post by Julien D »

Moving this from fork conversion to general q/a.
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CodyShires
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Tusk top end gasket kit

Post by CodyShires »

Does anyone know if you can pull that main KIPS shaft and change those two seals without tearing apart the top end?
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Re: Tusk top end gasket kit

Post by John_S »

I don't think its possible but even if it was, I personally would never try it. You got the kips valve bolted to the main shaft that's under the front cover that basically up against the frame, there's a little pin in there...and on and on. I would say install a new oring on the round kips slotted cover on the left side for now and then do those oil seals whenever you decide to tear it down.
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Re: Tusk top end gasket kit

Post by Julien D »

Aren't you replacing the piston and rings anyway?
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CodyShires
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Tusk top end gasket kit

Post by CodyShires »

Well i just did the top end. I was having trouble getting It to idle. Did a leak down last night and found that seal on the kips main shaft is leaking in the right side. I also found a really bad leak between the reed block and boot for the carburetor. I guess the little o ring made into the boot was bad because I couldnt get It to seal. Ended up tracing out the gasket on the other side of the reed block onto a piece of gasket material and made my own gasket. I’ve actually never had the kips mechanism apart. I’ve opened the covers and everything was always clean and not sticking. I was trying to avoid taking the top end apart since I just had It apart last week. But no big deal It doesn’t take that long
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Re: Tusk top end gasket kit

Post by Julien D »

Ah, gotcha. It's certainly easier to get into the KIPS system on a bench. I don't know that a small leak there would have very much effect on anything, though, except maybe a little spooge buildup right there. For my own piece of mind I'd probably pull it and install those seals, but you're probably also fine running it as-is for now.
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