$200 1980 KZ650 E1 Project

Hey all,

I bought this bike last fall in boxes for $200. It's been an ongoing project that i want to turn into my main bike. I get a little closer each day. . .

this is what i bought originally:


took it home, cleaned it up some, painted the frame:


installed the engine:




put the wheels back on:




figured out some wiring disaters (main hurdle so far. . .)


painted the pipes gold. yeah, i said it:






cut the old seat pan and foam down to make a solo seat and reapolstered. (pics to come)
ordered a new sprocket from Z1 (which came yesterday), drive chain, and brake light switch.

new sprocket on today:
old:


new:



i got it started a week ago after i cleaned and readjusted the gap on the contact breaker. my sparks weren't firing and i couldn't figure out why until i did that. the wiring is still a mess, but she's running. just waiting for that chain so i can take her down the road. . .

i don't have the stock exhaust and my 4 into 1 doesn't fit tight. i was thinking of making some exhaust flanges out of some spare aluminum i just bought (to make a back plate to cover up the wires and plastic i exposed because i cut the old seat down). any ideas?

also i don't think the #4 cylinder is firing. new spark, packs are good. where should i start with that?

let me know what you think. more pics to come.

- Gorham

Wow what a difference. Someone was running that old sprocket! I'd start by checking the compression.

Mark

When i first started riding i would buy a bike similar to yours and have to undo the repairs that had been done to the bike.
That can be a nice bike and look at all the expierence you get.
If you are not going to be riding it any time soon i would put some light oil in the pistons. Roy

got some pics of the seat i made:




and the seat pan i fashioned to cover up the back end:








new chain today as well:


how do i wire these lights into the stock harness? do i just split the new light wire off into two male ends into the two female ends of the stock harness?:


i did the compression test yesterday. here's what i got:

DRY
#1 - 75
#2 - 70
#3 - 90
#4 - 72

WET
#1 - 100
#2 - 85 (retested @ 100)
#3 - 100
#4 - 90 (retested @ 75. this is the cylinder that misfiring or not at all)

she starts right up though. runs rough, but not too bad . . .

i took her for a spin down the road and she dragged ass like crazy. i think its due to the exhaust leaks in the front because the 4 into 1 i have isn't a tight fit. i'm thinking of fashioning some exhaust flanges out of some spare aluminum i have from the seat pan. any other ideas?

I'd get new ones and use a high temp copper sealant to seal the outside. It is what I end up doing on my dirtbike as the 2 o-rings and crush washer only do so much for an engine that requires exhaust savaging for proper operation.

The solo seat has my interest. Now if you could put some springs on it.........

I was thinking of putting springs on the seat, but it kind of looks like overkill with the shocks too. eventually i'll get around to cutting a thin piece of wood the same shape to put under the metal so i can staple the vinyl down so its a bit nicer.

instead of buying a replacement side panel for the one i was missing, i fashioned up some new ones. . .











shes lookin pretty gnarley. i fixed my exhaust problem and got my #4 cylinder to fire as well. i have ok compression and good spark, so i took the carbs back off to see what was up, and it ended up being an upside down float! what an idiot! i heard someone on here mention before to check that when i was reading someone else's post. i was like "who would do that?" . . . .

so shes running on all 4 and much smoother now. i don't have the original vaccum system for this bike so i connected the ports with hoses and it cured my misfiring and sputtering.

just a little more clutch adjustment and she'll be good to go. got her on the road last week as well.

made some modifications since my last photo. pics to come.

started painting my tank:








sanded and primed. colors to follow. rattle can special.

what should i use to buff it out once i'm finished? what product & cloth? or should i get an attachment for my grinder?

couple coats of primer, wet sanded, couple coats of color, wet sanded, & a couple more coats of color so far:








i like how it really makes that dent pop . . .

There`s nothing like busting into things balls out!:woohoo: gitterdone and goog luck, keepon keeping us posted!