Tumbleweeds 1977 KZ650 Rebuild/Reform (Pic Heavy)

So I guess I'll settle in here, and begin the long thread that means to chronicle the rebuild of my 1977 B1 KZ650. I intend to rebuild the bike with a sort of vintage racing and European styling influence where the end result is a machine that appears as simple as possible. An engine, a chassis, a big tank and small seat, with minimal electronics.

This specific machine spent much time in Colorado, though has very little, if any, surface rust. It was passed from friend to friend and spent a vast portion of its life existing as a father/son project. Now it belongs to me.

This is my first KZ, so I am here to get the thoughts and opinions of those who know much more than I about these machines, and share my little project with you all.

Here she is as purchased:

My first project is to cut and wire a new set of bars, and those chrome fenders have got to go.

I also need to take off the carbs and go through them. The bike will idle but when you try to give it any throttle it bogs down and tries to die. Here is a photo of the sorry shape the pods were in.

The side plates on the bike are off a custom I believe.

These will be gone as the idea is that there is nothing behind these plates. Everything will be relocated to the tail cone or under the tank.

Bottom of the seat has a little rust.



Again that will all be replaced with the new seat/tail combo piece.

As it currently sits, wheels are coming off today, what are some good options on exhaust? Does someone make something that slips into the factory headers? The smaller the better as far as size, even a simple turn out is ok.

Tumbleweeds wrote: As it currently sits, wheels are coming off today, what are some good options on exhaust? Does someone make something that slips into the factory headers? The smaller the better as far as size, even a simple turn out is ok.

if you are looking for performance, A kerker header is a good way to go. there may be bolt on silencer options, you will have to measure your collector to know whats available. That stock exhaust looks pretty damn minty fresh. i would be inclined to keep that if i was you.

also the side covers are stock. what ever parts you end up pulling off you should sell on this forum, other members will appreciate it.

Anything I don't use will be put up on here for sure! The stock pipes are in great condition but they are way too big and bulky for the look I'm going for. I need a minimalists exhaust

Also is dim headlight common?

If you change the exhaust I recommend you buy a complete system rather than trying to graft something onto the stock headers. This is especially true if the stock exhaust is in good condition because you can sell it on eBay (good ones are getting quite rare) and use the funds to offset the cost of the new system. Also, a complete system engineered to work as a system will work better than a pieced together system of dissimilar parts.

A dim headlight is not common. Was that picture taken with the engine running? If not, it could be the battery is not fully charged. One thing to keep in mind, the original headlights were not halogen, so while not actually dim they are not as bright as halogen lights. The good news is that swapping to halogen is easy. Ed

Any ideas on a good exhaust that is literally as small as possible without going custom?

Also what do I do for rear sets with only a single bolt to mount? My footrests are extremely loose.

No eBay APP ID and/or Cert ID defined in Kunena configurationThe footrests have a notch that mates with a lug on the frame so they cannot slip. They use 12mm bolts, so they should be tightened to about 45 foot pounds. I can't imagine them being lose unless they were fiddled with be the previous owner.

About the smallest 4>1 I've seen on a KZ650 is the Harris pipe (see pic below). I don't know if they still make them, but I know Harris is still in business. JP Cycles may handle them. Once in a while one turns up on eBay. There's one out there now with some dents in the header (see link below), but it's i England so shipping might be too high. Ed

That pipe looks acceptable. Thank you for the lead, I'll look into a new one.

And as far as the footrests it does not seem to be the connection to the frame as it is the pivot of the footrest. I would like a pair of knurled metal rear sets to increase grip. That stock rear brake lever is slippery!