KZR's Bikes of the Month for 2024

Saving a '81 KZ750-E

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30 Jul 2021 13:50 - 30 Jul 2021 13:50 #852865 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I am using Wood Craft clip ons.  There is no room on either bar to clamp anything else.  I will bypass the wiring used for the hazard flasher circuits.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
Last edit: 30 Jul 2021 13:50 by Skidmark.

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30 Jul 2021 16:05 #852872 by Nessism
Replied by Nessism on topic Saving a '81 KZ750-E
My '81 750E uses the later type hand controls.  Pretty sure there is a hazard switch and the feature to alert the rider when one of the headlamp filaments burns out.

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30 Jul 2021 16:36 #852873 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I know the original controls had the hazard switch.  The new repops are for a Z1, and do not have that switch.  Thus I won't be using the hazard switch wires in the harness.  The wiring diagram for my bike is starting to piss me off.  I am finding connectors not in the diagram.  I didn't think getting the electrical sorted would be this much of a headache.  Did I day I hate wiring?  Well, I hate wiring... 

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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30 Jul 2021 16:55 #852874 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I found this connector, and the diagram lists it for a "warning light self checker".  It is coming out of the rear loom on the right side near the battery.  Is this for a factory diagnostic tool to plug into?  I can't find anything that has the same shape connector on the bike.
 

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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  • Scirocco
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  • Never change a running system
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30 Jul 2021 17:22 - 30 Jul 2021 17:27 #852878 by Scirocco
Replied by Scirocco on topic Saving a '81 KZ750-E
The warning light self checker connector need the same electronic divice like the rear break failure "idiot light" 

 
 
Last edit: 30 Jul 2021 17:27 by Scirocco.
The following user(s) said Thank You: Skidmark

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01 Aug 2021 14:15 #852990 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I ended up finding my warning light self checker.  I seem to spend the majority of my time looking for parts or fasteners to put this bike together.  I was "okay" at bagging and tagging everything, or so I thought.  Turns out I am only so-so at that task.  Note taken for the next project!

I finally got my left handlebar control all sorted and hooked up.  Once the battery is hooked up and the ignition turned on, I will test it out.  But for now, all the connections make sense to me.  Now on the the right handlebar controls...

I received some of my spark plug wire parts.  I am building my own wires.  I got NGK resistor spark plug caps, and the coil ends.  Hopefully my bulk wire will be here in a few days.  I still need oil to put in the crankcase.  Hopefully this thing wire fire up for the first time in the next week.  Not drivable, but will be able to hear the motor for the first time.  It' going to be a milestone moment on this project!

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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03 Aug 2021 10:20 #853075 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
As I draw near to firing up the motor, my intention was to turn the engine over without the spark plugs in, to get oil pressure before applying any spark or fuel.  I was thinking about using an impact gun on the right end of the crank.  In my mind this shouldn't have any issues or risks.  How long should the oil pump take to circulate oil throughout the motor and top end at low RPM?  30 seconds? 1 or 2 minutes?  5 minutes?  I used assembly lube during the rebuild, so is this overkill?  I'm not sure I trust the oil pressure light when it comes to getting oil throughout the top end.  I would love to hear some opinions on this.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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  • Scirocco
  • Offline
  • Premium Member
  • Never change a running system
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03 Aug 2021 14:08 - 03 Aug 2021 14:18 #853092 by Scirocco
Replied by Scirocco on topic Saving a '81 KZ750-E
An impact gun is not the best idea, you can shere off the bolt or location pin on the crank.
Use the starter motor until the oil pressure light gets off + 5 seconds to pump up oil to the camshaft bearings.
Repeat the the sequence 2 times and you are ready to fire up the engine, a short first start video would be nice
Last edit: 03 Aug 2021 14:18 by Scirocco.
The following user(s) said Thank You: Nessism, Skidmark

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03 Aug 2021 15:31 #853097 by calum
Replied by calum on topic Saving a '81 KZ750-E
Last time I did this I took the plugs out and just pushed the bike along the driveway in 2nd. Figured this would be easier on the 'dry' parts than turning it over with the starter.
The following user(s) said Thank You: Nessism, Skidmark

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03 Aug 2021 21:48 #853125 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I made a new ground strap from the battery to the engine.  One part I spent a lot of time searching for before I threw in the towel and made my own.
 
 

I  also finished wiring up the ignition coils.  Dynatek coils require a different connector than the stock.
 
 

The heat keeps me out of the shop in the afternoons.  Doesn't seem like much progress, but got to keep pushing forward.

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)

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04 Aug 2021 13:20 #853155 by Skidmark
Replied by Skidmark on topic Saving a '81 KZ750-E
I finished making up the spark plug wires.
 

Retired gearhead
'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker (lost in the shop fire)
The following user(s) said Thank You: gordone

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04 Aug 2021 13:55 #853156 by gordone
Replied by gordone on topic Saving a '81 KZ750-E
nice work!

What wires and caps are you using?

1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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