kz650/636 Hybrid

I obtained 2 kz650's last year. 1 was my dads, 1 was my dads friend. My dads had the engine ripped out of it and is now scattered all over the place in his attempts to get the bike back and running. The other bike was crashed and dropped of @ my grandparents 20 years ago. Engien apparently had soem work done to it back in the day and is intact and will crank. Neither has ran for that long. I currently Ride an 03 636 ninja and have done my fair share of research thanks to this forum, and because of my familiarity with the 636, ives decided to use those parts exclusively to upgrade.

Goal is to use 636 suspension, brakes, wheels, and rearsets. Everything else I think I wan't to keep stock to the KZ.

Heres some progress pics






the front forks are 100% mountable.
We took the old stem and pushed it out of the lower tree.
Welded and then turned down the KZ stem(where the lower clamps onto) 5mm larger then the 636 lower strem opening.
pasted some loctite on the stem. Heated the 636 lower up and dropped the KZ stem almost all the way in. Had to be tapped in gentely near the end.

The rear is not mounted as you can see. I am having a swing arm axle fabbed up to match th OD of the KZ swing Arm bolt. I know some of you guys used a spacer to do this. But Ive had lots of input from friends and family saying to make it 1 solid piece. SO its going to be done that way. Once thats done I will have to fine tune the center alignment of the swing arm into the frame. Then Add the 636 solo shock.

I dont know alot about Engines right now. But im a quick learner and easily teach myself with the guidance of others. I will need to look into an offset front sprocket. Hopfully 520's are available.

Will add the rearsets this week I believe, I'm not sure if i should w8 till the frame is rolling and @ proper hieght before I do that...

The seat will not look liek that. I plan on moving the plastic tail closer to the front and doing a 1of1 single rider seat. low profile.

Comments and Concerns Welcome

i like it that is going to be one cool little bike

You are doing fine...and you'll teach me something or two

I would provavly wait to mount the rearsets too. So you can get a feel of how the bike will sit before you mount them. Should be cool.

Looks great so far, keep us posted with progress.

Mark

Cool! I love retro/modern project bikes!

I love what I see, Continue with this way.

yuval

nice work

what year were those 636 parts you used, the forks and swingarm and such....i've got an '82 kz750 that i've been working on and what your doing is exactly one of the things i've looked into.

they are from an 03/04 636

They are not a direct bolt on though. There is alot of fab work that is required. So really, you can make almost anythign fit anything else with the right amount of work and will. IF you cant do it yourself take it to a fabrication shop and Im sure they would do it for you.

I was just hanging out with a friend who brought to my attention the speedo. It was my original intent to reuse the stock speedo and tac.
Now i havnt looked @ the bike to see how it was originally calculated but im guessing off the front wheel. I knoW for a fact the 636 is done off a sensor from the front sprocket. Any ideas how or IF I can even re-use the original speedo or do i need to go to something fancy and modern?

here is what i came up with kind of leaning towards koso



www.kosonorthamerica.com/




www.starlane.com/vedit/15/cronometro-gps...le~multifunzione~gps



www.electrosport.com/products/product-detail-1590.php