78 KZ650 C2/ 79 D2 Hybrid Brat

So some might realize that I originally posted my bike as a 77 C1, but after a little help from Ed and some research I found that the frame is a 78 C2 frame and the engine is a 79 D2. Was going to go simple and "rig" everything up, but during the course I decided to buy a mig welder and start fabricating my creation, could say a passion developed and now I am diving in.

So this is Day 1:



This was about a week later, nothing fancy:



I came across a Brat Kit made by a company called MonsterCraftsman,

and the kit is strictly for the Yamaha XS650 (seen in the picture above), the frame is obviously different. So I am making my own, it has been 6 years since I had been in any welding class but I believe I still have it in me to make good welds. Besides the frame mod, I can now easily attach the rear fender, the false oil tank for the electronics and the electric start panel, almost forgot about my seat I am almost done with it. Ill have pictures in a day or two, the hinge and springs are on their way, also found an instrument cluster on ebay for 30.00 and it is in good working shape.

Also there were pieces of gasket falling out from under the valve cover lid, I suspected RTV or something by the color, sure enough, there was no standard gasket I was cleaning everything I pulled off the tensioner bracket and one of the rubber bushing fell down into the space where the chain from the cams goes, any advise on getting it out, other than disassembly. Unless it completely has to be done.

Finally got some more pictures today, and I took off the lower end of the motor and fished out the rubber bushing, also stumbled across a Honda 650 motor and frame at my brother-in-laws house and they are moving so I'm going to see if he wants me to take it off his hands.

Enough of that, these are the pictures of where I am at now:
the current state of the bike is still a little rough




the cut tube on the backside of the 2nd picture was cut number one but it didn't leave me with enough room to work with so I cut to the down-tube, but now that I have a MIG welder I can get some real work done. Still waiting on the tubing though.


However I did get my seat pan knocked out, my new light came in, as well as the valve cover gasket, the gauges, kick-start and the mirrors. I found an old ammo can I'm going to try and use as an electrical box for the battery and mount the electric start.





I also had some time to clean up the shop a bit, partially due to a crazy Arizona monsoon type of flash storm, the roof leaks and I kind of forgot until it was raining on my head. I used an old above-ground pool to temporarily fix the situation.

The motor is super clean and hardly any wear on the upper end, I suspect the PO liked their rat bike.

I am working patiently with the screws for the cover around the sprocket on the left side of the engine, I also got the oil seals and the shift lever is leaking like crazy that is what has me messing with that



How do I go about getting the front sprocket off, also anyone know id the wheels from a Honda CB650, its a 78 and an A model if B-I-L is right, they are wire wheels and in good condition, so if anyone knows, any knowledge would be greatly appreciated.

So got everything except the tubing, the frames is ready and prepped:



Made a simple bracket for the Harley headlight:



Got the shop picked up and the battery box off the swing-arm:




and the gauges all wired back up, no pics of that

Nice job so far. this is something i would like to do also. Do you know what handlebars are on you bike now, that is what im wanting. thanks

I just took some 7/8" aluminum tubing with a 1/4" wall and made 7 degree bends, I had a steel set of bars, almost the same just heavier. Im going to try and do some copper bars and fenders after I get her back together

I decided to use the ammo box as a tool box for the bike and just make a box to fit the battery snug:

Still waiting on the tubing, it is coming from Wisconsin so it will probably be here tomorrow. Ill post pics after everything gets tacked together, but for now I got the engine 95% done, seemed to have lost an allen bolt for the cam chain tensioner

Got the new rear wheel bearing in and back on the axle:

and the frame married to the wheels and suspension, minus the rear shocks:



Getting pretty close to getting it all back together, does anyone know where to find wiring diagrams?

Here are KZ650 wiring diagrams. Ed

diagrams.kz650.info/wiring/WiringDiagrams.htm

So I started mocking everything up and here is what it is looking like:



found this nasty lady while cleaning up, actually found 6 of them, this ones body was about as big as a dime.

Has anyone filled in the emblem mounts on the tank with weld or sheet metal, if so any pointers, specifically for flux core welding or should I have someone TIG it? I don't want to cut the tank, just cut and lay a piece in there. also is 1" OD x .049 wall too thin to use to make my upper frame mod, like what I am mounting the seat and shocks to?

So I had a couple days away from the bike, the carrier bearing in my truck blew out so I was busy with that but today I got everything tacked together. I have been milling around some ideas and I cannot decide which way to go but I started this as a bobber project, I believe that's the way I an going to go, which means ordering more tubing....
From the left, don't be too harsh I got all this done in about 15 minutes, cuts and all





I don't remember if I had said anything about the color of the tank and how I wasn't digging it..... So this is about 10 minutes into the first coat of aircraft stripper. Use gloves this shit really burns

and I wish I knew this was under all 6 layers of paint, I like it but I started going at the tank with a sharp scapper, so the tank is either going to be black or bare metal but I need some votes because I cannot decide

Also sketched up this idea for a jockey shifter bracket that would allow me to engage the clutch with little effort but I am not sure if this would work. Any advise or pointer would be cool