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85/86 ZL 900/87 ZL 1000 Oil Pan Service

R. J. Apr 19, 2017

  1. R. J.

    R. J. Supporting Member

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    :hello: When I removed the oil pan these 3 parts fell out. Can anyone tell me of the location & which way do they go in. IMG_4090.JPG IMG_4089.JPG
     
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  2. R. J.

    R. J. Supporting Member

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    :hello: OK: I found out the location for the O-ring that is shaped like a toilet seat, :laughing7: but how does it stay in. IMG_4106.JPG IMG_4107.JPG IMG_4108.JPG
     
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  3. R. J.

    R. J. Supporting Member

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    IMG_4082.JPG IMG_4083.JPG IMG_4109.JPG :hello: While I did a search on oil pan removal but could not find any threads on this subject. Here are the drawings for the oil pan & associated parts. Pic 3 shows the 2 parts (marked in yellow) that I need to know how they go in.
     
    Last edited: Apr 19, 2017
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  4. R. J.

    R. J. Supporting Member

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    :hello: While I looked in both the ZL supplement & the GPZ manuals & neither has anything on these 2 parts locations 92075 & 92059. While I'm done for the night. I just hope someone can help me. :pain10:
     
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  5. Harriminator

    Harriminator Senior Member

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    :hello:Okay Sir, here we go:

    This o-ring/form ring is used only for models with oil cooler to seal the oil flow; coz Kawa ordered them parts obviously for all models it's an 'additional production gift' for all ZL-riders to make them nervous and think about what will be damaged as next...:laughing7: remove and forget it. You put it @ the right place but the milled alu connection makes it needless.

    The square little rubber piece is under this bowed little oil tube with an o-ring on each side - I found it as well in my pan and fixed it with superglue on this brazed metal piece @ deepest point of the tube to hold it in position by pressing of the oil pan when assembled.

    The little snorkle is a backflow hose and putting in right position it shows to the screen in the oil pan held by the nose to be shifted under this H-tube; there is only one hole in the oil pump where it fits.

    Oki-doki?:hello2:
     
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  6. R. J.

    R. J. Supporting Member

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    :hello: OK: Thank's. On the tube one end is sort of threaded. Which end goes up in the motor. Again Thank's. IMG_4090.JPG
     
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  7. R. J.

    R. J. Supporting Member

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    :hello: In the parts list the square that is dipped in on one side (part # 92075) & flat on the other states that it is a dampener. So you are saying that it goes under part # 32033A tube. How did you glue it. On the tube or in the bottom of the oil pan. Would a small zip tie be OK just to hold it in place. IMG_4110.JPG
     
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  8. Harriminator

    Harriminator Senior Member

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    Kind of threaded into the motor if I remember well (try and error), this nose must be close to H-tube; a drop into the dipped side and pressed onto that metal piece of the tube (oilfree for sure but not to mention).

    P.S. Maybe non-threaded up, looks more logical when H-tube should hold it (...may slip down in time coz not really fixed, some kind of improvement-case...)
     
    Last edited: Apr 20, 2017
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  9. R. J.

    R. J. Supporting Member

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    :hello:Thank's. I'll give a go at it. I think most likely that the threaded end screws up into the motor. The smooth end fits tighter into the oil pan than the threaded end does. Makes scenes A. IMG_4111.JPG IMG_4112.JPG This is the only hole/slot in the oil pan that the tube fits. I found the location for the square plastic dampener part # 92075 (See pic in post # 7. The oil pipe has a square tang welded to it. The dampener snaps onto the oil pipe so no need for glue. IMG_4113.JPG IMG_4114.JPG
     
    Last edited: Apr 20, 2017
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  10. Harriminator

    Harriminator Senior Member

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    :hello:Sorry, but somehow wrong: this snorkle comes from the oil PUMP and has to be turned in the screen direction of the oil PAN; when fixed you can put the H-tube into the holes of the engine and this nose on the snorkle is 'held' by the H-tube (somehow...). Yes, the damper snaps onto the oil part but will be 'washed away' by hot oil and you'll find it again in the pan, telling you.:laughing7:

    Explanation: when the pan is mounted and tight there is a gap between this damper and the pan which will be closed by heating expansion of the material; til this moment the oil has enough time to loose the rubber and let it 'snap out'. Was told about this in another forum by alex-germany who figured it out.
     
    Last edited: Apr 20, 2017
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  11. R. J.

    R. J. Supporting Member

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    :hello: I was wondering about that because when I went to put the oil pan on the other end had no place to go. Also the hole that I have the tube/snorkel in it feeds oil to the two external oil lines/banjo bolts. IMG_4120.JPG IMG_4121.JPG
     
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  12. R. J.

    R. J. Supporting Member

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    :hello: OK: here are pics of the oil pump & of the only hole that the plastic pipe/snorkel fits into. I have it aimed at the screen as you said. IMG_4124.JPG IMG_4123.JPG IMG_4125.JPG IMG_4122.JPG IMG_4127.JPG IMG_4128.JPG IMG_4129.JPG So post # 9 first section/part & first 2 pics are incorrect.
     
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  13. Harriminator

    Harriminator Senior Member

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    Hole is wrong, it's the one in your last pic between screen and tube you're looking at directly low left - but must be aimed to the screen mounted in the pan (with the 3 screws). This nose must be under the H-tube so non-threaded goes into engine.
     
    Last edited: Apr 20, 2017
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  14. R. J.

    R. J. Supporting Member

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    :hello: It's all coming clear to me now. :laughing7: I remember now that when I was removing the oil pan the D & D 4 into 1 collector was in the way so I reached up & twisted & pulled the tube/snorkel out. It has that nose/ foot/lobe/kicker (see pic # 1) that goes between the cross oil H pipe/line & the engine case as you said. This holds it in place A as you said A. IMG_4130.JPG IMG_4131.JPG IMG_4132.JPG IMG_4133.JPG So in post # 12 the black plastic tube/snorkel is in the wrong hole refer to pics 5, 6 & 7. Thank's for the help it is greatly appreciated. This whole ordeal has been nerve racking. Something I'll never forget. Time for a beer. :laughing7:
     
    Last edited: Apr 20, 2017
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  15. Harriminator

    Harriminator Senior Member

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    BINGOOOOOOOOO (Inglorious...:laughing7:).
     
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  16. R. J.

    R. J. Supporting Member

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    :hello: Thank's AGAIN :wav: !!! And B I N G O was his name O. I'm going to drink 2 beers. My last 2 from New Years. :laughing7: IMG_4134.JPG
     
  17. R. J.

    R. J. Supporting Member

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    :hello: While I was was going to make an Editorial on this subject. Even with my screw ups. :laughing7: For oil pan removal instructions refer to the ZL 900/1000 Supplement & the GPZ 900/1000 Service Manuals. If you do not have them they can be down loaded in the down load section of the FORUM. Post # 3 & # 7 has pics of the oil pans drawings. IMG_4063.JPG IMG_4069.JPG IMG_4073.JPG IMG_4081.JPG IMG_4085.JPG IMG_4086.JPG IMG_4087.JPG IMG_4088.JPG IMG_4089.JPG IMG_4091.JPG IMG_4092.JPG IMG_4097.JPG IMG_4103.JPG IMG_4104.JPG IMG_4105.JPG IMG_4115.JPG IMG_4116.JPG The OEM oil pan gasket is no longer available from KAW. I bought 2 from the ZL store & a non OEM one from E-bay. You will need 2 90 MM O-rings for this project. It is a good idea to put a very thin coat of gray RTV on the oil pan then place the new gasket onto the oil pan. Let it set up for an hour or so. In my case a day. :laughing7: This will keep the gasket in place while installing the oil pan. The oil pan screens on this bike was not restricted much at all. I found a few blades of grass in the round screen. :laughing7: Other than that this motor was very clean inside. I was told that this bikes oil was changed every 3,000 miles using AMSOIL.
     
    Last edited: Apr 20, 2017
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  18. kvalheim

    kvalheim Well-Known Member

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    How does grass get in the oil pan:wtf:
     
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  19. R. J.

    R. J. Supporting Member

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    :hello: That's what I was wondering. :laughing7: See for yourself in post # 17 pic & 5.
     
  20. R. J.

    R. J. Supporting Member

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    :hello: I picked up these to Kaw manuals a few years ago in like new condition for $60 shipped. IMG_4135.JPG
     
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