1978 KZ650 C2

After

Before

After

Before

After. As suggested, I protected the valve guides. Used short pieces of pencil inserted lightly into the guides.

Drayman, you have the bug. Love to see it, I'm similarly obsessed. I just recieved my first C model last night. It was relatively inexpensive and I got a ton of stuff, unfortunately in boxes. A real basket case. I am currently rebuilding a B model (all bikes are '77 650's) and this is what I do to dissassemble, if you don't want to pony up for the stands and engine mounts.

Just take everything off the back end with the center stand down. I lifted the engine out the right side after taking the top end out, it wasn't too bad. See new picture on next post . . .

Then I just used some jack chain to tilt the bike back off the front wheel and hooked the chain to an anchor in the concrete floor. Then you can take everything off the front!

I recieved a 1977 C1 with non stock parts like a 650 sr seat (doesn't really work with duck tail) an sr tank, and a '81 .738 liter engine, inline four. I'm not sure if it will all go together; it is really going to be a challenge. Particularly the electrical, but it ain't rocket science (I like to think it almost is, though, when I'm having difficulties!)

The bead blasting looks great. I'm not sure I would have touched the alluminum journals in the head where the cam rolls, but it all sure looks new!

On getting out of the basement, I'd carry it piece by piece, too. Couldn't you drive it up the stairs like the dude in Animal House? My next door nieghbor built an airplane in the basement of his house. Fusealodge (sp?) and wing were separate when he removed it buy knocking out part of a basement wall. He then chained the fusealoge to a big oak tree and fired it up in his front yard. This was '74, when I was 10. Mortorcycle? There's always a way if you want to do it. I love the guy above's suggestions. Sounds fun.

Hey Mountain:

Thanks for posting pics of your assembly design! Definitely a great suggestion. I'm thinking that when I get to that point I'll join frame and engine in the basement, and then have my buddy help me carry that much up the stairs into the garage. I have a bike lift which I can then use to assemble the bike.

No worries about the cam journals in the head. I just tried to clean up the gasket sealing surfaces. Stayed away from jorunals and stuff like that.

Any idea how I can remove that really stubborn left over cam cover gasket from the head? If you look closely, you can just make it out near the lower left portion of the top of the head.

drayman86 wrote:

Here's a shot of the engine. I got the cam cover off and removed the cams, also removed the head bolts. Can't get the head off, and I don't wanna pound or pry for fear of damage.

There is a least one bolt inside of the head below where the cams run.

I guess you found the bolt. . .late to the party.

:huh:

Post edited by: KaZooCruiser, at: 2007/02/22 18:49

There is a spray on gasket remover at Napa. Spray librally so it soaks in and wait over night. Carefully scrape with a super sharp chisel.

Do they make a C1 specific manual? I love manuals, I pour through them. It is good to have two different kinds, just to cross check. Did I send you this motorcycle maintanence link? It has helped me some and is a great reference:
www.dansmc.com

mountain wrote:

Do they make a C1 specific manual? I love manuals, I pour through them.

So do I. I keep my Clymer manual in the Can.

I'll check out the gasket removal stuff from the auto parts store this weekend if I have an opportunity. I know enough NOT to scrape on gasket sealing surfaces.

Dunno about the C1 manual. I've got another version of a factory service manual coming. Maybe it covers the C1; I'll let you know. If so, you can always ask me questions from that manual if it's applicable to the C1.

Speaking of Can, you'll have to excuse me. I'm turtle-ing here at the keyboard. :pinch: