78 KZ650 Project needs serious TLC
- Rory Byrd
- Topic Author
- Offline
- User
I ordered the Clymer manual and am awaiting its arrival. This weekend I am going to drain the gas, feed her some good gas and give her a quick bath. I'm going to pick up a new battery and see if she wont turn over and start for me.
Anybody got anything else you would recommend checking while I wait to get the service book? I was thinking of getting to work cleaning up the engine and doing cosmetic work. What do you recommend using to clean the engine of all the oxidation? I've got plenty of "elbow grease" but was wondering if there wasn't some compound or trick that might help me keep a good stock of "elbow grease" after I've finished cleaning the engine.
I've attached a couple photos of my new bike. I will take some better shots this weekend. If there is anything you think I should post a picture of let me know. I am going to need all the direction I can get. I've got ADD so an action course would be great!!
BTW I am looking to try to make this into a cafe style bike. If that helps any....
Thanks for all the help.
P.S. If this is by chance in the wrong category, let me know/feel free to move it to the right category.
Attachment photo.PNG not found
Attachment photo1.png not found
1978 KZ650 B1
Please Log in or Create an account to join the conversation.
- Patton
- Offline
- KZr Legend
- Posts: 18640
- Thank you received: 2098
The FSM is imo superior to Clymer.
Routine service schedule should be in either manual.
Would also do a forum search for soda blaster.
Good Fortune!
1973 Z1
KZ900 LTD
Please Log in or Create an account to join the conversation.
- KZJOE900
- Offline
- Admin
As for cleaning the aluminum, I like Mothers Mag & Aluminum polish. Works well by hand. You can additionally use a buffing wheel on a drill along with the polish for the hard to clean spots. Or you could get some cutting/polishing compound (for soft metals) to use with the buffing wheel. Good luck.
Current project 76 KZ900 (This was a Vetter model)
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450
Please Log in or Create an account to join the conversation.
- harm
- Offline
- User
- Tom
- Posts: 681
- Thank you received: 13
The condition is very close to the condition of my 550 when i started, it took me a while but it looks great now(see my avitar pic).
Have fun and keep us posted!
Tom
Holland, MI
1980 KZ550 ELR
2011 Concours14
2017 KX450 [/color]
Please Log in or Create an account to join the conversation.
- 650ed
- Offline
- User
- Posts: 15344
- Thank you received: 2829
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Please Log in or Create an account to join the conversation.
- Rory Byrd
- Topic Author
- Offline
- User
1978 KZ650 B1
Please Log in or Create an account to join the conversation.
- 650ed
- Offline
- User
- Posts: 15344
- Thank you received: 2829
Rory Byrd wrote: Thanks for all the information! I think I did write down somewhere that we were going to change the oil and filter. Ed, is that something that is simple enough to do without having the Clymer book, or should I wait. My dad (who is the brains behind this project) knows motors and motorcycles pretty well. Do you think its something that between he and I, it would be a pretty simple thing to do?
Below is a link to the Kawasaki Service Manual for the KZ650-B1. Your bike is newer, so the stuff related to the alternator and charging system doe not math you bike. However, the oil & filter change is the same. Be sure to use the appropriate torque (and torque wrench) when tightening the fasteners or you may end up with stripped threads like many others have found. Also, only use oil that is marked on the bottle that is meets the JASO-MA standards; that is important for our bikes because of the wet clutches. Be sure to have the bike on the center stand when you fill the oil and make sure the level is between the two lines on the little round window - don't over or under fill.
Another thing - the screws on your KZ are not Phillips (I know they look like Phillips, but trust me; they are not!) Read the following posting regarding the screws:
kzrider.com/forum/21-tools/532335-budget...ewdriver-tips#532335
KZ650-B1 Kawasaki Service Manual:
www.scribd.com/doc/48655900/Kawasaki-KZ-...B1-77-Service-Manual
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Please Log in or Create an account to join the conversation.
- Rory Byrd
- Topic Author
- Offline
- User
We have decided that once she is running, we are going to strip the bike, paint, do any frame work, and rebuild with the look we want. But I think I might just re upholster the seat and ride her for the rest of the summer before trying a full on rebuild.
We'll see how this weekend goes with replacing the starter solenoid and go from there.
And in case you were wondering who "WE" is, this is a project I am doing with my dad.
1978 KZ650 B1
Please Log in or Create an account to join the conversation.
- Rory Byrd
- Topic Author
- Offline
- User
Its not exactly what I expected, but its what I got.
Over the weekend, I replaced the FORD starter solenoid with the right KZ solenoid and that got the starter working. After we saw how gunky and gassy the oil was, we decided before we try to start her that we were going to take off the carbs and give em a good cleaning. Once we got the carbs off we saw that the previous owner, or a previous owner had removed a lot of the gas lines/plugs and not replaced them.
The air box is in pretty rough shape so I think we are going to put individual air filters on each carb. I like the look and think it will be better than the clunky box.
We also noticed the throttle return cable was in poor shape and we need to order a new return cable. So this week I am cleaning carbs and waiting for more parts! At least I have something to do while I wait for my parts and wont be sitting idly by.
I will take some pictures tonight to show you guys what we've found or not found in some cases.
1978 KZ650 B1
Please Log in or Create an account to join the conversation.
- 650ed
- Offline
- User
- Posts: 15344
- Thank you received: 2829
BTW, here are some pics of KZ650s with those hideous airboxes. I don;t know how anyone could stand to own such a thing....
Attachment 000001.jpg not found
Attachment 000002.JPG not found
Attachment 000003.jpg not found
Attachment 000004.JPG not found
Attachment SnowBike1.JPG not found
Ooops; how did that one get in there? :blush:
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Please Log in or Create an account to join the conversation.
- Rory Byrd
- Topic Author
- Offline
- User
I take it you are a Kawasaki purest? Stock is the way to go, right? There is nothing wrong with the way those bikes look. In fact, if my bike looked like any of them (especially the last picture) I would be thrilled.
There is another contributing issue leading me to the pods and that is the (?ports?) coming from the airbox to the carbs are all cracked. And to replace them is more expensive than the pods I found. If you know of somewhere I can get those parts for under $30 then I am happy to keep the airbox. I was just trying to keep it simple and inexpensive.
You have some great input and I really do appreciate it. I'm new to this so forgive any ignorance. LOL.
1978 KZ650 B1
Please Log in or Create an account to join the conversation.
- 650ed
- Offline
- User
- Posts: 15344
- Thank you received: 2829
Yes, I guess you could say I'm at least a semi-purist on my bike (I have made a few mods that don't show), but you will notice some of the bikes I pictured are far from stock. I was serious about using the airbox to establish a baseline. If your bike currently is running poorly it could be caused by any number of things. Sorting them out IMHO is best done by beginning with a full tune-up. This eliminates a bunch of variables and may even solve the problem. However, if it does not solve the problem you may need to try a bunch of tests (compression, charging system ignition system, carb issues, wiring, etc.) before you locate the source or sources of the problem. If you install pods before you get the bike running well you introduce yet another variable that must be considered. Further, it is well documented that the KZ650 (and pretty much all KZ's) will not run well throughout the rpm range with pods unless changes are made to the carbs. Doing this requires making jetting or other carb changes then testing the performance, and if the performance is still not quiet right repeating the process until it runs well. Trying to do this on an engine that already is running poorly will make the chance of success near zero because even if you get the jetting correct that will not solve the original problem that is causing the bike to run poorly, so you won't know you hit the right jetting combo. If you don't want to buy new air ducts you may even consider temporarily taping over the cracks in the old ones (not pretty, I know) until you can get the bike running properly. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
Please Log in or Create an account to join the conversation.