Saving a '81 KZ750-E

I am wondering whether or not to use the Kawabond 5 sealer on all the gaskets that retain oil - clutch cover, output shaft cover, oil pan, valve cover, etc. My only reservation is if something has to come apart it's a PITA to clean the surfaces and replace the gaskets. I am going to use it on the cylinder block base gasket. I could go crazy and use it everywhere, just not sure if it's really necessary.

Not sure if this helps at all. This is the Kz1000 FSM. It’s calling for a similar torque.

The only places I used sealer are where the factory service manual calls for it. On the head gasket for example in specific locations.

This sucker is getting heavy again!

Are you going to rebuild the clutch hub with new dampers?

Actually, I haven't addressed the clutch yet. Still wrapped in rags from disassembly. Probably clean and inspect it in the next day or two. I need to reblast the clutch cover and refinish it, too. It's too large of a surface to leave pitted. I was hoping it would look better painted, but I'm not happy with it.

Here is the reason I blasted the new paint off the clutch cover. I really should have addressed this before painting. Foolish to think it would look better painted.

I have never done body work before. Anyone with experience on aluminum have a recommendation? I will not use heat for fear of warping the cover, so solder or lead fill is not an option. I may swing by or call a local shop for advise as well.

Give this a try, it works well.

More stuff on the way. I missed a couple of o-rings, and also ordered piston ring compressors, A.P.E. cylinder head nuts (to go with the new studs), and cylinder head washers. I can't move forward on assembly without the o-rings I overlooked, so trying to get the clutch covered redone, and start cleaning and inspecting the clutch assembly.

I was looking for a metal filler that I could then powder coat over. I think I was contemplating how to fill big scratches on a caliper body.

I never actually used it, but this product claims to be ok with powder coating, if anyone has a need for that.

www.alvinproducts.com/Product-Line/aT/Vi.../6/Hi-Temp-Lab-metal

I have used JB Weld (Original, NOT quick set) with GREAT SUCCESS as filler before powdercoating.
There are a few steps involved however.
The depth/size of the pitting, scratches, or imperfections that need "filling" will determine the procedure.
If just a few shallow pits, I apply the JB weld, let it sit for 24 hours then sand/blend into surrounding area, just as you would Bondo.
Sanding the primer with 500 grit. Small amounts of JB weld do not seem to shrink or outgas enough to matter.
Deep, large areas I will fill with JB Weld, and "Pre-Bake" the part to allow the JB weld to cure/bake/outgas. Large areas tend to shrink a bit so another sand is then necessary.
Sand
Final Colour. I build tattoo machines and use it to fill out gaps.

My baby wants her heart put back!