1977 KZ650 B1

I should have started this thread a year ago when I picked up this bike. I picked up my first bike, a 78 C2 two years ago when I started riding. I couldn't have asked for a better first bike. It's been a strong runner and I've never had a problem or breakdown with it (Knock on wood). Someone approached me one day as I was pulling up to work and mentioned he knew someone who had the same bike sitting in a garage for 20 years and wanted to know if I'd be interested in picking it up cheap. Had a stripped spark plug thread, which is the reason I'm assuming it was parked and never run again. I said sure and a couple of days later I had this 77 B1 sitting in my dad's garage. I figured you never too old to learn something new, and it would be handy to know how to fix my bike if I ever had an issue with it.

Let me say that I am in no way mechanically inclined, I didn't know anything about engines, let alone motorcycle engines, but this site and the people on it were an incredible source of patience and information to my questions. I read as much as possible and stopped and asked questions when I was stumped.

First thing I did was tackle the carbs. They were nasty. #2 and 3 had fuel/syrup sitting in the bowls for 20 years. The jets had crystals on them, and the slides were fused.

As suggested on the site, I made sure to label everything carefully to make sure I didn't mix parts from different carbs. Armed with a lot of carb cleaner I went to work.

Z1 Enterprises is were I sourced 99% of the parts. Great prices and excellent service. Those guys know their bikes.

With the carbs sorted out, I needed to deal with the largest issue on the bike, the #4 spark plug thread was completely stripped. I'm guessing it's the reason the bike was parked for so long. I read a lot about Heli-Coils but I ended going with a Time-Sert kit and I'm happy I did. Worked like a charm and it was easy for this rookie to use. Also made sure to check valve clearance while the head was off and everything was within speck.

The tank had some serious rust in it. I followed the guide that gets posted on the site regularly and it worked like a charm.


Didn't look too bad, but rinse after rinse of hot water kept resulting in brown murky nast stuff pouring out.



This was the final step which worked amazingly well. Came out good as new.

Head went back on and torqued as per the FSM with new gaskets. Double checked the valve clearance before I put the cover back on.

Exhaust back on with new gaskets.


Tank back on with new cheapo petock, and inline filter.

Here I am attempting to fire it up for the first time. I can't believe it started. Right after I ran it for a while it developed a leak from pretty much all the cam end caps. So I ordered a new set, then had to wait a loooong time because of a Canada post strike.

Once the cam end caps came in I got to do this.



What an amazing feeling.

Excuse the shorts, it was 40 Celsius out while I was working on the bike and I just wanted to take it for a quick spin.

Now for the aesthetics, dents, paint etc. and a new seat, although, I have to admit it's comfortable.

Excellent. I bagged me a 1977 B1 about 18 months ago and am making slow progress with it.
Bought it to do as a passtime rather than throw loads of money at it and have it turn into a museum piece. I intent to use it as a daily ride and not just for sunny Sunday afternoons.
Your photos suggest that the cylinder head can be removed with the engine in the frame. My manual seems to be saying you have to remove the engine from the frame to do this. How did you manage?

CrazyHarry wrote: Excellent. I bagged me a 1977 B1 about 18 months ago and am making slow progress with it.
Bought it to do as a passtime rather than throw loads of money at it and have it turn into a museum piece. I intent to use it as a daily ride and not just for sunny Sunday afternoons.
Your photos suggest that the cylinder head can be removed with the engine in the frame. My manual seems to be saying you have to remove the engine from the frame to do this. How did you manage?

Harry, throw that Clymer or Haynes manual in the fire and get a Kawasaki service manual. In it you will see very specific instructions on engine disassembly with the engine installed and a separate section on engine disassembly with the engine removed. The real manuals are available on eBay, just be sure to get one that contains your exact year/model as there are differences in the various KZ650 models. Ed

Cool. Thanks. That should speed things along a bit.

Yep you definitely can pull the head without removing the engine. Listen to Ed, that's the best advice anyone could offer. The FSM is the most important thing you can buy to help you along. You know it has to be good if someone like me can get a bike running. They should run about $20 on ebay and worth their weight in gold.