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KZ650 cafe-racer 07 Jun 2021 10:59 #849754

  • gazzz
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On Saturday I finished two last covers for the aforementioned engine and I am anxious to share some photos of them.

Alternator and ignition covers are relatively small and of pretty simple configuration compared to other engine covers, so it may seem that it’s pretty simple to polish them. However, these covers  have areas that have to be painted and this fact provided me with an additional issue to solve, since painted areas have to be completely clean before paint is applied. But first, let’s proceed to photos “after and before”. Here they are:

 

 

 

 
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 07 Jun 2021 11:01 #849755

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Preparation for polishing I started as usual, from dry sandpapering. It showed a lot of flaws, which was no wonder, since both covers are more than 40 years old. Scratches, dents and spots of corroded aluminum – that all pretty expected things for such parts. 

 

 

Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 07 Jun 2021 11:02 #849756

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Slightly unexpected was only a light warpage of ignition cover.  I fixed the issue using a sheet of sandpaper placed on a mirror (thing flat enough to plane the cover contact surface).

 

Then was habitual drill: dry sandpapering, wet sandpapering, polishing, sandpapering again and so on and so forth up to the satisfying result.

 

 
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 07 Jun 2021 11:05 #849757

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The most unpleasant thing is the points of corroded aluminum. I call them age spots. They are ordinary things for old aluminum and they eat their way deep into the metal. They are not critical for the parts usage, but one never could get rid of them. And since in such  points aged aluminum changes its density, they will be visible after polishing.

  Once I finished with polishing, I cleaned areas that had to be painted, masked covers as thorough as possible and then went with them to the nearest glass beads blasting shop. The media they have loaded in their machine was coarser than I wished, but with two small covers and a wish to get them ready ASAP I had not much of a choice. After glass beads blasting I “shook off the dust” from my airbrush and painted covers, still masked with satin black Eastwood ceramic engine paint. After this the most difficult task was to keep my hands away from the covers until paint became dry.  The last part of the work on covers required extreme accuracy, as I have to sandpaper letters but touch not already polished aluminum or paint in deepenings. Same accuracy was necessary to polish letters. To ensure better resistance of paint, I “baked” covers before I started polishing.The result of this was my personal  great satisfaction. This is the point where I encounter a lack of words to describe my opinion on the subject. Let’s say it in this way: covers are not perfect. But they are perfect in their imperfectness.  So let’s take another look at them. Here is ignition cover:

 

 
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 07 Jun 2021 11:07 #849758

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The “age spots” I mentioned earlier.

 

And as I already wrote, this version of Kawasaki logo is my favorite:

 

I also cleaned the ignition cover a bit from inside.

 
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 07 Jun 2021 11:11 #849759

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And here is alternator cover:


 

 

Let’s take a closer look at it too.

 

And yet closer one

 

With all engine cover ready I indeed could proceed to engine assembling and I already made some preparation works.
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com
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KZ650 cafe-racer 07 Jun 2021 15:14 #849778

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Looks great Gazzz, I prefer the old KAWASAKI logo too....!
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KZ650 cafe-racer 07 Jun 2021 16:42 #849792

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WOW, just plain WOW!!!
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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KZ650 cafe-racer 08 Jun 2021 15:45 #849844

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Those look fantastic! 
A breeze from the west.
‘90 ZR550 Zephyr aka Zephanie
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KZ650 cafe-racer 08 Jun 2021 22:39 #849867

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Those covers look totally awesome, great work !!!
79 KZ 1000 LTD
77 KZ 1000 B1 LTD (awaiting electrical resurrection)
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KZ650 cafe-racer 09 Jun 2021 12:50 #849905

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Thank you guys! I really appreciate your good words about my work!
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com

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KZ650 cafe-racer 21 Jun 2021 13:30 #850545

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Time to continue the story.
Kawasaki KZ650 cafe-racer: in progress

Kawasaki Zephyr 750 (810ccm, 4in4, spoked wheels)
Honda CB815 "Eight Fifteen" cafe-racer
Yamaha XJ "Eight Ball" cafe-racer

www.gazzz-garage.com

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