Rebuild parts questions

[Dolomite_]

I've seen a few people mention that the typical full engine gasket/seal sets are missing a few things. What exactly are they missing? I've got it from here because of no stock in some other places https://www.bertrumsbikebits.co.uk/product/honda-cb-400-4004-cb400-4-cb400f-full-gasket-set/.

Is it worth replacing the cirlips? If so how many are there exactly?

What other small things do you normally miss?

I'm placing a big order with yamira so don't want to have to end up paying another chunk for shipping on a few missed things.

so far I've noted these in my google sheets file:
cam chain
Cam chain tensioner blade
Cam chain guide blade
Cam chain tensioner blade damper rubber
Camchain tensioner arm
Clutch lifter plate bearing
Cush drive rubber
Engine oil seal kit
Exhaust silencer to collector box gasket
exhaust downpipe to collecter
Exhaust No. 3 down pipe to collector box clamp
Exhaust No. 1 down pipe to collector box clamp
Exhaust port gasket
Oil filter
rubber damper
exhaust collar

[McCabe-Thiele (Ted)]

If you have dismantled the gear shafts I would replace those circlips pretty sure the size is in the parts book iirc.
Two obvious ones that come to mind are the ones on the end of the clutch unit and the kick start shaft.
I suspect one aftermarket gasket set will differ in content to another brand. A lot of shaft oil seals and O rings are extra to the gasket sets. None include the oil pump O rings but you might already have bought the kit from Nurse Julie.
Other thoughts are the head gasket thickness might affect the corresponding O rings that you fit on the head.
Oil sump pick up pipe O ring.
I would spend some time looking through the parts book to double check stuff like the two small parts that the tensioner blade sits into etc.

You might get lucky with a member who has made a complete list

[Laverda Dave]

In addition to Ted's comments;
You will need the three o-rings for the oil gallery plugs, they are a unique size and are Honda expensive.
The Haynes manual states to renew the circlips and thrust washers on the gear shafts if the individual gears are disturbed.
Don't be tempted to re use the piston circlips!
My gasket kit did include the oil rail o-rings in the top of the cylinder head as well as the inlet manifold o-rings (4-off) and the exhaust header to head gaskets.
I re-used the 'U' shaped tensioner cushions they were fine on inspection.

[Bryanj]

Primary chain and primary cush drive rubbers, although cheaper to buy kawasaki primary from fowlers, also the special sealing washers for two of the head nuts

[Dolomite_]

Primary chain and primary cush drive rubbers, although cheaper to buy kawasaki primary from fowlers, also the special sealing washers for two of the head nuts

Cush rubbers are about £10 from yamira. What are the special washers?

Do you have the part number for the Kawasaki cush rubbers?

[McCabe-Thiele (Ted)]

The Doughty washers I guess on the cylinder head bolts - a sort of washer with a rubber section?
The four large O rings on the liners where the base gasket is - mine were not in the gasket set that came with my 400 they were either missing or not included.
Seal kit's do not always include the rev counter drive oil seal - like lots of seals available online if you have the sizes.

[Bryanj]

Not Kawasaki cush ribbers but Kawasaki primary chain, part number has been posted on here many times

[Laverda Dave]

My High Level kit came with the barrel o-rings but the head gasket was badly marked and unusable.
It all depends on the kit you buy to what is supplied but when you get it check the head gasket is in good condition.

[McCabe-Thiele (Ted)]

The Kawasaki Primary Drive Chain Part Number is 92057-1011 fits the 400 (23131-323-000) iirc.

I am not sure if this is correct for the 500 as my parts manual shows it as 23131-323-000 so the same as the 400 but written above the parts book number  is a hand written amendment to 23131-426-003 DS seem to also show the part as per the amendment.

Bryan or another member might be able to explain the change in part number for the 500. In a previous post Graham stated it was a superceded part number on the 500 - possibly stronger?

[Dolomite_]

Not Kawasaki cush ribbers but Kawasaki primary chain, part number has been posted on here many times

Ahh I miss read you. Yeah I found the Kawasaki primary chain mentioned and have got one already. Not bad saving half the price!

[Deano400]

This is a list I started to put together a while back. Can't remember if it's complete or accurate but may help you putting your list together.

Diagram      Part No.   Description                            Quantity
Gasket Set            
D1   107   16173-253-004   Carb insulator O-ring 27 x 2.4             4
C1   277   91302-001-020   Tappet cover O-ring 30.8 x 3           8
D2   18   12209-333-005   Valve stem seal                                   4
C2   31   12909-333-000   Cylinder stud seal                           2
C2   32   12910-333-000   Oil orifice seal                                   2
C2   276   91301-377-000   Cylinder base O-ring 55.5 x 2           4
C2   14   12191-377-000   Base gasket                                   1
C1   19   12251-377-000   Head gasket                                   1
C1   24   12391-333-000   Rocker gasket                                   1
C1   22   12329-333-010   Breather gasket                                   1
C1   275   91301-333-000   R oil way O-ring 7 x 1.7                   1
D2   280   91305-333-000   L oil way O-ring 5 x 1.7                   1
E1   8   11394-377-000   Clutch gasket                                   1
F2   9   11398-333-020   Sump gasket                                   1
G2   12   11691-333-000   Alternator gasket                           1
Oil Seal Kit            
A2   265   91201-300-003   Crank oil seal 30x42x8                   1
B2   266   91201-323-005   Crank oil seal 30x45x8                   1
C1   267   91201-324-010   Tacho oil seal 6.5x14.5x7                   1
E1   268   91202-216-005   Clutch oil seal 14x24x5                   1
E1   269   91204-259-000   Kick start oil seal 16x28x7                   1
H1   270   91205-333-005   Drive shaft oil seal 34x52x13.5x15.5   1
H1   271   91206-286-005   Gear change oil seal 14x28x7           1
H2   272   91207-333-000   Mainshaft oil seal 34x9                   1
Oil Pump O-ring Kit            
H2   278   91302-044-010   Oil Pump O-ring 6.9 x 1.5                   2
H2   279   91302-377-000   Oil Pump O-ring 15 x 2.5                   2
H2   215   41123-516-00   Oil pump O-ring 63 x 2.5                   1
Separate Items            
B1   45   14401-333-003   Camchain                                           1
G2   140   23131-323-000   Primary chain                                   1
G2   139   23114-323-000   Primary drive damper                           8
E1   238   90431-292-000   Washer.Lock 16mm                           1
G2   239   90433-283-000   Washer.Lock 6mm                           1
H1   240   90435-333-000   Washer.Lock 8mm                           1
F2   287   91329-590-003   Sump filter O-ring 16.5 x 2.8           1
C1   242   90442-377-000   Seal Washer 18od x 2.2 x 8mm thread   2
F2   283   91315-044-000   R main oil way O-ring 19.4 x 2.8           1
F2   286   91319-300-000   L main oil way O-ring 13 x 2.5           1
F2   282   91314-220-000   F main oil way O-ring 16.4 x 2.4           1
H1   213   35751-333-003   Neutral switch O-ring 11.2 x 1.8           1
A2   285   91317-703-000   Camchain adjuster O-ring 6 x 1.7   1
C1   30   12905-333-000   Oil pipe holder                                   2

[Deano400]

F1    274    91301-283-005    Clutch push rod  O-Ring  5x2.4          1

[Bryanj]

Not so much misread as not to well tryped on the dumfone, in my defence it was at the end of the shift.
The primary gear cush rubbers have increased in price quite a bit over the last year but are a must to keep chain good