'81 650 Project

I figured it was about time to start a buildish thread on my bike. I have posted quite a few tech question on getting it running, so I figured people would want to see what it looks like.
Pics of when I got it...



Recovered the Seat, looks pretty good I think

27,000 original miles

The Ignition Advance Module was froze, so I freed it up.


After having the carbs for the 4th time, I finally did it right. Bench Sync'd them too

Not too dirty...it will do




Well just about an hour ago, I got it back assembled, and went to fire it for the first time (again). Ill let the video do the talking...

All I can say is im a happy camper! Ill be working as much as I can on it so its road ready by hopefully June.

welcome to z-jungle!

Thanks man! Im glad to be a part of the z club.

After some research, I removed the "Clean Air Paraphernalia" and bridged the valve cover breathers, and capped the left over vacuum nipples. That clean air thing seemed like a joke.

Now I need to rebuild the front forks, get the front brake finished (just add fluid), re-attach everything, new tires, new gas tank cap (where do I find one on the cheap? college budget), and get it licensed and insured!

What will I need to rebuild the front forks? I am pretty sure there is no oil left in them, I filled them with the correct air pressure to see if thats all it needed, but they are still springy.

those are called leading axle forks ,do you have a manual?
while you have the frontend apart id suggest repacking or replacing the front wheel bearings.
checking front brake pads,flush old brake fluid/bleed brakes.
pull the triple trees off and repack steering head bearings.
pull rear wheel and do the same,check swingarm bearings while back wheel is off and grease em up.
basically start at one end and check everything till you get to the other end ,could save lots of headaches later

Well I had the front brake assembly off last year, had everything beadblasted, and painted. I also bought a new caliper and did the same to that. So the front brake is all ready to go. I had the front tire off already to replace the tube, and while I had that off, I was going to re-pack the bearings, but they are the sealed type, so I took them to my dad, and he inspected them and said there was absolutely nothing wrong with them.

I do have a manual, Clymer, Ill look at that sometime soon and check it out. I have finals all next weeks so progress will be at a standstill for at least a week or 2.

.

ShouterVW wrote: ...I need...new gas tank cap....

What's wrong with the cap?

Sometimes, cleaning the vent plus a new gasket, makes a difference.

Good Fortune!

.

Congrats on getting her running! The gas cap should be pretty easy to find (I would try eBay) as Kawasaki.com lists it as part #51048-1018 and says it was used on the following models (double check compatibility before buying):

KZ1000-A3 (KZ1000) (1979)
KZ1000-A3A (KZ1000) (1979)
KZ1000-A4 (KZ1000) (1980)
KZ1000-E1 (Shaft) (1979)
KZ1000-E2 (Shaft) (1980)
KZ1000-J1 (1981)
KZ1000-J2 (1982)
KZ1000-J3 (1983)
KZ1000-K1 (LTD) (1981)
KZ1000-K2 (LTD) (1982)
KZ1000-M1 (CSR) (1981)
KZ1000-M2 (CSR) (1982)
KZ1100-A1 (Shaft) (1981)
KZ1100-A2 (Shaft) (1982)
KZ1100-A3 (Shaft) (1983)
KZ1100-L1 (LTD Shaft) (1983)
KZ250-D1 (KZ250) (1980)
KZ250-D2 (CSR) (1981)
KZ250-L1 (CSR Belt) (1982)
KZ250-W1 (LTD Belt) (1983)
KZ305-A1 (CSR) (1981)
KZ305-A2 (CSR) (1982)
KZ305-B1 (CSR Belt) (1982)
KZ400-H1 (1979)
KZ440-A1 (LTD) (1980)
KZ440-A2 (LTD) (1981)
KZ440-A3 (LTD) (1982)
KZ440-A4 (LTD) (1983)
KZ440-D1 (LTD Belt) (1980)
KZ440-D2 (LTD Belt) (1981)
KZ440-D3 (LTD Belt) (1981)
KZ440-D4 (LTD Belt) (1982)
KZ440-D5 (LTD Belt) (1983)
KZ440-G1 (1982)
KZ550-A1 (1980)
KZ550-A2 (1981)
KZ550-A3 (1982)
KZ550-A4 (1983)
KZ550-C1 (LTD) (1980)
KZ550-C2 (LTD) (1981)
KZ550-C3 (LTD) (1982)
KZ550-C4 (LTD) (1983)
KZ550-M1 (LTD Shaft) (1983)
KZ650-H1 (CSR) (1981)
KZ650-H2 (CSR) (1982)
KZ650-H3 (CSR) (1983)
KZ750-E1 (1980)
KZ750-E2 (1981)
KZ750-E3 (1982)
KZ750-F1 (LTD Shaft) (1983)
KZ750-H1 (LTD) (1980)
KZ750-H2 (LTD) (1981)
KZ750-H3 (LTD) (1982)
KZ750-H4 (LTD) (1983)
KZ750-K1 (LTD Belt) (1983)
KZ750-M1 (CSR Twin) (1982)

Patton wrote:

ShouterVW wrote: ...I need...new gas tank cap....

What's wrong with the cap?

Sometimes, cleaning the vent plus a new gasket, makes a difference.

Good Fortune!

Well, the bike never came with a cap! So I definitely need one.

Thanks for the kind words everybody!

Martin, I hope your ready to answer some questions on the bike if I ever have any! The forks seem like theyre going to be a pain in the ass.

Ill definitely replace the rear shoes while I have the rear end taken apart.
The parts list as of right now looks like:
-Fuel Cap
-Front fork seals
-Front Fork Oil
-Rear Brake Shoes
-Petcock Rebuild kit
-Front and Rear Tires (rear one looks good, but who knows how old it is)

Also, as you can see from the first few pictures, my tank is in pretty rough shape, a pretty sizable dent on the side there, I was wondering if you think its salvageable? People on ebay seem to want an arm and a leg for a tank for this bike...I can't afford that right now.

With the front fender removed, steering may become unstable. Go to www.fastfromthepast.com and get a front fork brace.

MFolks wrote: With the front fender removed, steering may become unstable. Go to www.fastfromthepast.com and get a front fork brace.

The front fender will be going back on soon, It will go back to almost 100% stock, except for the handlebars...they need to go.