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TOPIC: 81 kz650h1 project "test pilot"

81 kz650h1 project "test pilot" 24 Feb 2019 12:05 #799142

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I still need to remove and figure out taillight exhaust, finish theframe, shave random un needed mounts, whew, I can see why these can take a minute to build

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81 kz650h1 project "test pilot" 25 Feb 2019 13:14 #799189

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Worked on the wiring a bit today, making sure I have everything working before I figure locations and such.

Here is my wiring diagram right now, does this look alright? I have also posted in the electrical area
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81 kz650h1 project "test pilot" 13 Mar 2019 13:40 #800278

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Finally got a couple nice days so I took some time and wired her up, trying to get it to fire up before I tear it down to finish up the frame.
Not having any luck, good spark and compression, fuel down the cylinders it gives a bit of a backfire but no actual "run" just a backfire. I'm thinking the valves may be stuck?

But my headlight works !!
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81 kz650h1 project "test pilot" 13 Mar 2019 18:23 #800304

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Did you rejet & tune the carburetors for the individual pod filters?
If so, what main jets & pilot jets did you install and did you shim the jet needles to raise them?

Other stuff. service fuel level check to make sure the fuel level in each carburetor is correct.
Accelerator pump operating correctly >> fuel should squirt thru the carb bores without hitting the walls.
Mechanical synchronization >> throttle slides adjusted the same or about the same. the slides have a square opening or notch that probably should be completely above the bottom of the carb bore. I don't recall what the 81 manual says about the throttle slide gap, but the drawing doesn't show the notch.
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81 kz650h1 project "test pilot" 14 Mar 2019 13:35 #800346

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I actually went back to the stock air box, decided I'd skip the hassle of fighting with jetting, may play with it after I have ridden it some, the carbs have been cleaned and gone through.

I'm thinking maybe there is an issue with the timing, I removed the cover that goes over the pickup coils, and it is fairly oxidized in there, I'm thinking there may be an issue with the timing advancer. Unfortunely someone has been in there prior to me and stripped the screw heads, was late so I just gave up for the night. I'm hoping to be able to remove the screws with some vice grips, or possibly slot them and try a straight slot screwdriver.

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81 kz650h1 project "test pilot" 14 Mar 2019 13:51 #800347

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If the pulsing coil plate screws are damaged, use a dremel to cut slots in them so that a screwdriver can be used.

The KZ650-CSR came stock with electronic ignition, so there's nothing to set. What you should do, though, is clean, check & lubricate the timing advancer. check that the springs aren't stretched or damaged or anything. separate the rotor from the advancer body, clean everything, then lubricate the advancer & fill the groove with grease. lubricate the spring ends & pivot points. Reassemble & check that the advancer operates smoothly. hold the body, then turn & release the rotor >> it should snap back. Use a torque wrench to properly torque the advancer bolt. Install a new engine cover gasket.

Important note: Put a 17mm wrench on the big crankshaft nut to keep the crankshaft from turning, then use a 14mm wrench to remove the advancer bolt. You must use both wrenches. Do not turn the crankshaft using the 14mm advancer bolt >> timing advancer damage could occur.
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81 kz650h1 project "test pilot" 14 Mar 2019 14:06 #800348

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Any recommended lube for the advancer itself? Or just a light greasing?

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81 kz650h1 project "test pilot" 14 Mar 2019 14:07 #800349

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This is what it looks like, I dont feel the oxidizing is "normal"
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81 kz650h1 project "test pilot" 15 Mar 2019 06:08 #800372

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Looks like it's been wet, maybe from sitting outside w a bad gasket. It should be clean in there with only minor oxidation.
I would use a penetrant on the screws. and vibration. heat from a heat gun might help as well.

Timing advancer lube. I use high temp brake & wheel bearing grease. dielectric grease & white lithium grease didn't work. doh.


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81 kz650h1 project "test pilot" 15 Mar 2019 10:50 #800386

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See that was my instinct. Spray some white lithium and call it "lubed". I plan to mess with it some this evening, fingers crossed lol

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81 kz650h1 project "test pilot" 26 Mar 2019 14:38 #801083

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Well this happened
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81 kz650h1 project "test pilot" 26 Mar 2019 15:09 #801085

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WHAT HAPPENED?
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

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81 kz650h1 project "test pilot" 26 Mar 2019 16:28 #801090

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I got it running and noticed fuel running out thr overflows, I thought I had cleaned it all up, went to fire it up and it backfired through the carbs and lit up the air box, cooked the wiring and side panels and airbox before I could get it out, also burnt through the roof of my brother in laws shed I have had it in

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81 kz650h1 project "test pilot" 26 Mar 2019 21:12 #801103

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HOLY SHT :ohmy:
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

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81 kz650h1 project "test pilot" 27 Mar 2019 05:21 #801108

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That bites. Are you going to forge ahead with the project? If so, the 81-83 650-CSR & 80-83 750E/H models used the same airbox. You can probably find a good used wire harness on EB. Replacement side covers for the csr are readily available & if you need the plastic electro cover, that should be easy to find as well. Anyway, sorry to hear about the setback. :blush:



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81 kz650h1 project "test pilot" 27 Mar 2019 06:25 #801111

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The project will be moving forward, just a little more in depth now, thanks for the heads up about the airbox, that was my biggest concern, I really dont want to have to play the jetting game.

Of course that happens when I'm about ready to bring it to my buddy's to do the welding and such. Such is life. Time to push forward, the melted plastic should be a treat to clean up lol

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81 kz650h1 project "test pilot" 27 Mar 2019 06:52 #801113

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The carburetors need to be very clean. Crud from the fuel tank can affect a float needle, causing an overflow.

I would set the fuel level to 3.0mm as per the service fuel level check in the manual. A simple carb stand can be made from 2.x4s w 2x6 base plus a couple of L brackets & bungee cord. Some hardware stores have free scrap wood. A lawnmower fuel tank could be used as a temporary fuel supply. or a large funnel & tubing. I got a good plastic tank from a mower service shop for 5 or 10 bucks..

The 81 650-CSR VM24 carbs don't need a special tool to check the fuel level >> just attach clear tubing in place of the overflow tubing & open a drain screw. The #2 carb has 2 ports on the float bowl >> one for the overflow & one for checking the fuel level or draining the carb, so you don't have to remove the overflow tubing on #2.
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81 kz650h1 project "test pilot" 27 Mar 2019 14:57 #801144

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You sir are a gentleman and a scholar!

Thank you for all the info. The carbs were mostly clean, I was only trying to run it to make sure it ran before it was getting a complete tear down for paint and a good cleaning of most everything. I guess this will make me think twice about doing that lol.

Pulling the bad stuff off tomorrow, hoping I can get the motor out, then she goes to my buddy's garage. I mostly was working on it here just to not bring a "turd" there (most of our friends do). I have the knowledge to build it, but only half the tools. He has the knowledge, garage, and all the tools lol. Once it is there she will be much better, my days will be less often to attack it, but the hours and what gets done will be more if that makes sense.

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81 kz650h1 project "test pilot" 27 Mar 2019 18:51 #801156

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Sorry to hear about the mishap... glad you can keep moving forward on it though. Hope your brother in law is the understanding type. :)

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