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TOPIC: 81 kz650h1 project "test pilot"

81 kz650h1 project "test pilot" 12 Feb 2019 14:17 #798553

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Figured I should get around to posting my build.

Here she is, 1981 kz650h1
Got her for 100$
This is how I brought it home, not much to look at, but she will get there
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81 kz650h1 project "test pilot" 12 Feb 2019 14:19 #798554

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Rockybalboba wrote:
Got her for 100$


What a steal!!!

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81 kz650h1 project "test pilot" 12 Feb 2019 14:21 #798555

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Got home and started taking stock of what was missing and what I wanted to change.
At this point I was missing throttle cables and assembly
Also needed plugs and wires
Battery
And some love

And then after some debating....


Oops. This fell off
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81 kz650h1 project "test pilot" 12 Feb 2019 14:23 #798556

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I didnt think it was terrible, it's fairly clean in the motor, everything rolls good by hand. Figured it was worth a shot

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81 kz650h1 project "test pilot" 12 Feb 2019 14:25 #798557

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The wheel rims are looks like aluminum high shoulder rims.

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81 kz650h1 project "test pilot" 12 Feb 2019 14:26 #798558

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Started playing with some ideas and visions


I liked the coffin tank
But it was a little long, and it belongs on my dad's trike so I didnt wanna cut it up on him. The seat meh, just the closest shape to the seat style i want on hand.

I like the shape of the factory tank, and I tossed my sled bars on it, actually kinda looks good.
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81 kz650h1 project "test pilot" 12 Feb 2019 14:27 #798559

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Possibly? They are spooked and do have some "oxidization"
Is that a bad thing?

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81 kz650h1 project "test pilot" 12 Feb 2019 14:30 #798561

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nothing a good polish and elbow grease can solve.

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81 kz650h1 project "test pilot" 12 Feb 2019 16:44 #798568

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Those are the stock wheels. 48-spoke w aluminum rims. If the spokes are very bad/rusty, you might be able to get them zinc coated. Someone suggested that to me just the other day, but I don't know anything about getting that done.

Probably jumping the gun, but are you going to weld a hoop or something to the rear. otherwise the frame will be kind of weak.

Rear brake shoes. you probably ought to plan on replacing the shoes. the adhesive that binds the linings to the shoes gets brittle over time & can fail, so a lining can separate from a shoe, then get jammed between the shoe & drum, locking the rear wheel. it happened to me, so it does happen.

....
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81 kz650h1 project "test pilot" 13 Feb 2019 01:58 #798584

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martin_csr wrote: .

Probably jumping the gun, but are you going to weld a hoop or something to the rear. otherwise the frame will be kind of weak.

Rear brake shoes. you probably ought to plan on replacing the shoes. the adhesive that binds the linings to the shoes gets brittle over time & can fail, so a lining can separate from a shoe, then get jammed between the shoe & drum, locking the rear wheel. it happened to me, so it does happen.

....


I do plan to do a hoop across the tail, still working out what I'm gonna do exactly lol.

And good advice about the rear brakes, I'll have to add them into my next parts order. That was something I hadn't even thought of, havent even seen it throw a spark yet, but the parts are coming in and my mind is racing, so it will get somewhere

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81 kz650h1 project "test pilot" 13 Feb 2019 07:22 #798590

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I would focus on getting the engine running. and if you need a manual.....

Kawasaki KZ650 service manual. jarlef z650. the 1981 KZ650 pdf manual is in the Files section.


....

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81 kz650h1 project "test pilot" 13 Feb 2019 09:04 #798596

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Thanks! I will be saving that link, my main focus is getting it going, but I had to order parts to even "attempt" to "start" it.
I havent had a chance to get to my buddies to get a compression test done, but soon hopefully.

Fingers crossed the motor is good, looks good.. but looks can and have been deceiving

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81 kz650h1 project "test pilot" 13 Feb 2019 09:55 #798599

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I have the same motorcycle. Here's some of the stuff I did:

Clean tank. fresh fuel. New fuel line w in-line fuel filter. new vac line. K&L petcock rebuild kit.
New air filter & cleaned the airbox. Airbox ducts good & soft. Good carb holders.
Cleaned the carburetors by removing the float bowls & the little parts. Checked the compression while the carbs were off the motorcycle.

New spark plugs. added small amount of oil to each cylinder thru spark plug holes. Redo the spark plug wire connections at all points.
Cleaned, checked & lubricated the timing advancer. New RH engine cover gasket after servicing the timing advancer.

New engine oil & oil filter.
Lubricated the drive chain & aired up the old tires.
New battery. properly serviced prior to installation. I did the battery last, because I wanted it to be as fresh as possible.
...
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81 kz650h1 project "test pilot" 13 Feb 2019 16:24 #798610

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Planning to snag some new fuel line aswell as vacuum lines. My carb boots are in awesome shape, supple, not stiff, I pulled the carbs out but I havent dove into them yet.

Been reading through the service manual, now that I have access to that I'm gonna go through and inspect what I can before I even attempt to roll it over "under it's own power"

Also. Some parts arrived today
Throttle assembly
Pod filters
Plug wires and boots

Still awaiting new throttle cable and spark plugs

Hopefully this weekend I will be able to get out to the shop and throw a couple wrenches at her. No heat in the shop makes me lazy lol.

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81 kz650h1 project "test pilot" 14 Feb 2019 05:49 #798631

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If your airbox is good & complete, do not throw it away as you might want to use it later or sell it: the 81-83 650-CSR and KZ750E/H models used the same airbox. If the ducts are good & soft, save those as well as they are NLA & only used on the 81 csr.

You probably already know this, but with the individual pod filters the carburetors may need re-jetting. Someone else can probably give you a good starting point. maybe #105 main jets & #17.5 pilots, but I haven't tried to remember exactly what others have used. doh.

....

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81 kz650h1 project "test pilot" 14 Feb 2019 06:10 #798633

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Pods. Egads. Good luck, but as Martin recommended keep the airbox and ducts handy so when you get tired of spending money and fiddling with pods you can reinstall them so the bike will run right.

As an afterthought, I must ask - Why pods? Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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81 kz650h1 project "test pilot" 14 Feb 2019 13:43 #798665

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No specific reason really, I try to pod everything lol, I just always like the looks of carbs with pods.

Also, I'll have a tough time (I feel) with hiding my electrics and battery with the air box right in the way. I do have it and it is complete and in decent shape from the couple minutes I saw it while removing it, and the boots where soft, idk about tears, wasnt really a thought to "save it" so I didnt look.


Is it really that bad running pods? I understand tuning can be trial and error. But I sprung for them since I've always had great results with my sleds and quads.

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81 kz650h1 project "test pilot" 14 Feb 2019 15:11 #798670

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Typically, although there may be exceptions, pods work well at certain RPM ranges but not at others. So if a bike is being raced carbs may be tuned to run well at high rpm using pods or velocity stacks even though at low rpm there may be less power. Of course nobody races at low rpm so it doesn't much matter.

I'm sure some folks love pods, and some may have found jetting combos that suit their needs, but there was a rather thorough study done a while back that cast doubt on the effectiveness of pods. See below. Ed















ALSO..........
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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81 kz650h1 project "test pilot" 14 Feb 2019 15:40 #798671

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Woah cool! Something to learn! Thanks for that, I'll definitely be giving it a read

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81 kz650h1 project "test pilot" 24 Feb 2019 12:04 #799141

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We have ignition!
Couldnt get the ignition working, and I really wanted to roll the motor over and get some ignition out of it before stripping it to clean up, so after some hacking and slashing, it starts. Not fully running, but it burns fuel.

Also, slight view of what I got for stuffs
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