88 K75s runs then cuts out

[Jethroww]

Hi Laitch, I have removed the intermediate housing and this is what I found on the clutch housing.
Would this be normal for an engine with 72,000 KM on it? I also have taken some pics of the starter
 sprag clutch gears. It seems to turn freely.
  Thanks

[Laitch]

Would this be normal for an engine with 72,000 KM on it?

Beats me, Jethroww. Maybe kennybobby, Gryph or someone else will chime in. What's unsettling to me are the unidentified objects on the images of the splined shaft. Are those sand grains, sugar particles, metal shards, lubricant droplets or just image artifacts?

[Jethroww]

Hi, They look like brass/copper and shiny/chrome pieces. It looks like the water/oil pump has been rebuilt?
Here are some more pics. What I found doing the first oil change.




I thought I would re-torque the impeller bolt since I had it apart. The bolt then broke.
After I removed the remaining bolt I found some metal shavings in the end of the shaft.






Cleaned everything up and reassembled. Ran the bike for about 2 min and another oil change.
Found no signs of any metal particles with a magnetic oil plug.
Do I have to replace the clutch nut/o-ring on reassembly?
 
  Thanks

[kennybobby]

i saw that and wondered if it was brass--but from where would it come?  Definitely looks crunchy in there.

Less is better when it comes to rtv gasket material--looks like a big wad of excess got ground up in the coolant.  A very tiny bead is plenty.

[Martin]

+1 Looks like too much sealant, are the particles soft or hard. Over use of sealant can, and has destroyed plenty of engines.
Regards Martin.

[Jethroww]

Hello, That was from the previous owner. I use The Right Stuff from Permatex(black).
A small bead in the centre/inside of bolts and will spread when tightened. Will re-assemble
and see how she runs. Should I inspect/clean the spraque clutch? Anything else while apart?
  Thanks

[Laitch]

Welcome to Jethroww's Housing of Horrors.

It seems prohibitively gritty in there but if you're satisfied that it's clean, Jethroww, you're master of your fate and captain of your soul. Clutch nut, o-ring and seal would be appropriate for reassembly. To clarify, you've had it running recently? It's getting difficult for me to keep up with your swiftly flowing pictorial odyssey.

[Jethroww]

Hi, I had it running for about 10 min total. It sounded to my ears that something was grinding.
So I started to investigate to find the noise. From my research I think now that is the normal
sound of the K bike. But as you say I have found my Housing of Horrors. The last time it ran it just stopped.
The engine seemed to be seized. Wound not turn by the rear wheel, wrench on the cam shaft.
When I tried to remove the clutch housing nut it finally started to turn.The engine seems to spin freely now.
I have no idea why it was running about 2,000 RPM and just froze? No miss fire/rough running etc.
Just stopped and would not turn over until the clutch nut removal. I will
spray some WD-40 into the sprague clutch and start the reassembly.
   Thanks