KZ650 Sleeper Build (KZ1000 engine transplant)

Got the bottom end installed into the 650 frame today. Sitting on a service cart so I can park it off to the side.





I need to build it up so it has the head bolted down so I can take it to a friends to have the exhaust welded up. I am fabricating a 4 into 2 system with a cross over pipe that will bolt to some stock looking chrome mufflers.

Trying to get it finished to ride it next season.
 

Got the triple trees installed and all the motor mounts torqued to spec with anti seize on the threads.



Mock installed barrel and it looks like I am about .010" shy on my base gasket thickness to be at zero deck. Will cut another gasket that puts the pistons -.003 to .005" down. Have a gasket paper that is a better thickness, will also cut a clutch gasket at the same time.



Put some grey heat shrink on the DIY threaded rod motor mount bolt, looks better and will keep the crud off it.

It took a bit but I have the cam pathways ground for clearance and the head ready for paint removal.





Final found out what brand the cams are, was working on them by a window with the sun shining in and saw there was stamping on the sprocket mount.



They are Russ Collins 400 but the lobes measure .418-.420" lift, one lobe 418 and one lobe at 420 but the rest of them are 419. I am usually looking on the cam ends for numbers, not too often I see them on that flange and its very faint unless I have my glasses on

Never clued in they could be RC, he made parts mostly for Honda's but he did campaign a Z1 Pro Stock bike early on.



Now have to dig up some info on them, a timing card or just the duration specs would be sufficient but could always just find out on the engine with a degree wheel.

I think this head is Z1 or KZ900, I don't think its KZ1000. The only ID it has is its stamped 62, don't know a lot about the big bike parts.


 

Found the cam info by searching on here :



Actual duration is expected to be between 260 to 270 degrees. These are a NOS set, never been run, found them on Ebay. I am setting up the head as shim under (650/750 guy) but hoping the cams are not too "hot" as I am wanting some bottom end grunt

I cut this gasket for the starter motor cover the other night.

For the life of me I could not find where I put the original, its around here somewhere and I have looked everywhere but have yet to find it.



It was bugging me (not being able to find it) so I had some 1/8" cork gasket sheet sitting here for over 25 years and I finally used it. Cut it out with a scalpel in about 10 minutes then glued it on the cover with good old Gasgacinch. Cork is not the greatest but it should keep out any crud from getting under the cover, and its better than nothing.

For the edges that showed I just went over them with a black marker pen.

This gasket from Kawasaki was over $30, or you can buy a repop cover and gasket for over $50... No Thanks, probably cost me less than $1.

Now I can put it out of my mind, next thing you know it will show up somewhere stupid!

Not much doing on this one right now.

Hope to advance on some parts that need fabricated : Turn some telfon piston buttons, and mill some 3/16" 1018 exhaust flanges for the head pipes.



 

I prepared the pistons today, got them balanced to within 1 gram, they all weigh 227g.



Also added some extra oil holes (smaller than what was there) and marked the piston numbers on the insides. I do need to increase the chamfer on the liner openings as they are now a bit too small after being bored. Then I need to check the ring gaps and make any corrections.



Correct thickness DIY gasket from bulk sheet roll sprayed with Copper Coat.
 

Started turning the Teflon buttons for the pistons today. Instead of grinding a radius form tool I laid out the face profile on my computer and came up with a cross section that used a straight angle for the relief required to match the piston OD, it came up as 8 degrees.



I drilled a #32 hole in the center and left about a .20" diameter land around the center.



I got half of them finished, will complete the set tomorrow.


 

I turned these little clamping buttons for the M5 bolts that hold down the Dyna 3 ignition plate today. This just give the maximum clamp area and takes up some thread length so I did not have to shorten the bolts.


 

Getting interesting. Nice work

Mikaw wrote:

Getting interesting. Nice work

Thanks.

Now that Winter is fast approaching I should be able to spend more time on it.

Got to finishing the last 4 of the Teflon buttons today. This was a bit of a chore on my tiny lathe as the compound rest locks are under the tool post cross slide. Every time I have to do a angle cut its a whole procedure.

Not sure but I think these buttons are a bit of cash now for a complete set, maybe $60-80 not including tax/shipping. 

The material to make a set is about $10.

 

I'm with you, I'll take a little time as opposed to spending money whenever possible