1978 KZ650 Bike Build

Looks good, what paint did you go with?

Tremclad Hi Heat Semi Gloss.  I need to go to a city to buy VHT.  Will use it on the brake calipers.

The Tremclad is a good match.  

Running into a few hiccups.  I put all the engine mounts in place except the rear upper.  It's about a half diameter off the hole.  Not sure why...all the other ones fit easily and there is no obvious damage to the frame.  

I moved onto setting the timing.  Everything went well but I need 5 shims that I don't have so I ordered parts to convert to shim over bucket.  Waiting for them to arrive.

Still waiting for a new swingarm bolt so cannot work on the back end.  That left the front end.  It all went together quite well.  The triple tree is from a Z1.  The fender was a bit rusty but otherwise OK, and it cleaned up nicely with a bit of Mothers polish.

 

You may just need to rock the motor using the play in the other engine mounts to get that last bolt in.

I tried that...kept them all loose but it didn't work.  So I drilled the hole in the mount a tad bigger.

The swingarm bolt arrived but I need a bushing.  The old one is frozen to the remaining bolt shaft.  I found one on ebay and ordered.  Should arrive in a couple of weeks.  Not much that I can do without it so I decided to check out what the bike would look like when complete.  It was a useful exercise as I discovered that my sidecovers for a B2 are not the same as a D1, which is the frame I'm working with.  I have the right one but had to order a left one.  I also discovered there is a difference in the tail piece....D1 frames are not made for one.  So it will sit in the spares box for now.  

 

Coming along well.


The D side covers are taller in height, they come down lower in the triangle of the frame tubes.
One peg mount on the covers is in a different location too on one or both sides.
Some have managed to fit the tail to a D model 650.
The seats are different though, to allow the tail to fit behind.

The bushing arrived and the swingarm is now properly installed.  While waiting I began working on wiring.  The main harness had been unwrapped so I was left with a bit of spaghetti to figure out.  I have the front of the bike done but am having a bit of trouble with the other end.  Could someone show a couple of photos of how the harness attaches to the frame under the tank and near the battery box?   

These may help:

Ed's C1:

Thanks Ron.  They were very helpful, although I have both flasher units on the left site.  (This is a D1). But he right side photo was very useful.  

I've been working on wiring for a couple of days now.  The headlight, brake lights, signals and horn are all operating correctly now.  

The Coquihalla highway is finally open again after last November's rain storms, so I drove down to Chilliwack to my favourite Vapour Blaster for a little engine cleaning.  It always amazes me how a thorough cleaning can make an engine look new again!  This engine won't go into the rebuild project, as I already had one ready to go.