I took my 94 (W/ 17,000 miles on it) down last week to check and replace the Dreaded O-Ring with the Kawasaki Part that I had Sean send. I installed Marks Exhaust at the same time so I had him send new exhaust gaskets too. I also did the Cycle One Off Mod, it came with a new pan gasket and the more solid, longer button / spacer / stand off to go at the bottom of the Main / Secondary Oil Galley Pipe.. Sure would have been nice to have some real instructions for this job. I called Sean in the middle of doing it to be sure I didn't screw anything up. He, as always was more than happy to help.
I didn't have to remove the oil level sensor as the wiring was long enough to reach the floor still connected to the pan.
There's no way you can just pull the pipe down to get at the O-Ring without further work. I backed out the 2 front bolts holding the Main / Secondary Oil Galley "The Pluming" in place. I didn't pull them all the way out.
When I got to the third, rear bolt, I applied quite a bit of force, trying to move it in both directions. I had a 500 Suzuki Titan that had a left hand thread on the connection of the oil injection. That's when I called Sean. He told me it was a standard right thread, just apply more force. When I did it finally came off. There's a weird copper washer that's held on just above this bolt. Again, I didn't take the bolt all the way out. At this point I could pull the pluming down but still lacked the clearance to R&R the O-Ring. The oil pump and pickup hold the primary pump pipe in place and that pipe stops further movement, at least on mine. Check yours first..... 3 allen head screws hold this in place. I backed them out about 1/8" so the primary pump pipe could drop just a bit.
I removed the orange stock ring and put some oil on the Kawasaki O-Ring to install it. It's sort of a snug fit. A much wider and tougher O-Ring than stock.
I pushed the Main / Secondary Oil Galley back into place, insuring that the smaller O-Rings on it's branches reseated where they needed to be. I tightened the 2 front bolts, then the rear. I cleaned the bottom of the pipe, where I'd removed the stock rubber spacer. Put a tiny bit of the Black RTV at the bottom and inserted the Cycle One Off Plastic Spacer. Next, I re-tightened the Oil Pump / Pick up, gradually going in a circle until the 3 screws were tight at the same time and same amount.
My old pan gasket was stuck to the engine rather than the pan so it was a PITA to get off. I used a small amount of Black RTV on the pan side for the new gasket to be sure it would come off that way next time. That was good because I opened it back up the next morning, just to be sure everything was secure and in place. It worked quite nicely.
Note, As Sean has mentioned, I don't believe any damage was done to my engine having the side of the O-Ring popped out of place. It still had enough oil flowing to survive. I did gain overall oil pressure after the job was completed but not to an extreme. There were no metal shavings in the oil or pan.
If this helps one person, I'm a Happy Camper....:biglaugh:
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