KZ650 Sleeper Build (KZ1000 engine transplant)

Only got a couple of things done today as I discovered my new chain was about 1 link short. Not sure if the sprocket on a 1000 sits slightly forward VS a 650 but the chain was ordered at the normal length I get them for a 650, I am even using a smaller (-4T) than stock rear sprocket. Front sprocket is +1T which would not make much of a difference but it still did not fit!



Luckily I had a low mileage 530 chain as a spare which I can use in early days while I reorder a slightly longer O ring chain. Will probably use that shorter chain on another 650 build. Got the chain and chain guard installed ready for the road.

Found a 650 sprocket cover with a clutch rod actuator and spring ready to use sitting in a spares bin. Was able to just take that actuator and put it on the 1000 sprocket cover but had to call it quits before I could get the cable on it and installed on the bike.

I snowed here this morning but it melted pretty quick, cold and dreary so just stayed inside.

Was able to cover my opaque vent lines with black heat shrink.



The high temp line sheathing arrived, perfect fit for the oil cooler line. First time using such a item so will see if its worth doing.



I put the two inner rubber ducts on the air box to mock up the oil lines on the bike. The lines will drop down in front of the air box and between the box and the carbs. Looks to be plenty of clearance. Will mock up with the gas tank installed to make sure there is room for what I am planning.



The top fitting on the air box is for the stock fresh air system, I bored out the ID's on that fitting to take a bigger vent line. The main crank case vent line is now 17mm, I believe that is up from 10mm. The additional cam cover vent line is 10mm ID, both join up to a catch can under the frame backbone.



The opaque vent line inside the air box joining up to the modified elbow fitting.
 

I was able to work on this a little today and found some issues on the oil cooler line routing.

Looks like the plan I had to install the lines prior to assembling the top end is not going to work as there is less room under the tank than I had initially imagined. I mocked up the lines with the air box sitting where it was with the CV carbs attached, which is in a forward position (can adjust up/down and fore/aft with adjustable brackets) The air box I am using is for a later 650/750 with CV carbs, its 3/4" shorter than the round slide carb version so it can be moved around a bit.

I found out there is room for the lines to sneak under the front of the tank and behind the coils into the center under the frame backbone. I tried to fit the lines above and beside the coil but its just too tight. The only thing I might have to move putting the lines in the middle of the frame is the oil vent catch can. This will only be found out once the cam cover is in place.

I have decided it may be best to plumb the lines when the carbs and air box are in there final positions as the fit is just too tight. I also found I may need to run some straight fittings into the top of the case rather than the angled fittings pictured.

 

 

 

 

 

 

 

 

It's moving along - won't the coils over heat mounted that way ? (no heat sink for the cores)

Wookie58 wrote:

It's moving along - won't the coils over heat mounted that way ? (no heat sink for the cores)




 

That is how they came stock from Acell, those coils have been in use on my 650's since 1985 with no issues. I did replace the mount nuts at one time because they were stripped but they never came with any stand-offs. The coil body does not touch the frame mount tab, there is a air gap on the mount straps.

That´s the reasson why i relocate the coils away from the heat if some place was left over on the frame.

 
 



 

Thanks for that photo Scirocco.  I may move my coils to that nice big space behind the side cover where the chain oiler tank was so many years ago!  

Scirocco wrote:

That´s the reasson why i relocate the coils away from the heat if some place was left over on the frame.


 

The "heat" I was referencing is that generated internally in the coil during operation. Many coils rely on the chassis mount of the laminated iron core to dissipate heat during running. Unless you are running "Acell" coils I would advise caution in mounting this way

I would be using the same mounting holes, bolts, and spacers.  They will bolt to a bracket I'll make attached to the frame.  Similar to Scirocco's first picture (behind the side cover).  Or I may decide to leave well enough alone!

I could make the coil mounting a bit better but I know they work and its never been a issue. Maybe something to do down the road when I get time.
The Acell coils are kind of unique in that they rely on mounting "straps", there are no molded mounting holes.

There is zero room on the 650 to do any coil relocation unless you get rid of the tool tray behind the battery box. Even then it would be very tight, the 650 is much more compact than a Z1.

That is the issue I am finding with the oil cooler lines, just not enough room as compared to the Z1. Of the few pictures I have of Z1 engines in 650 frames, the oil line routing under the front of the tank works but is tight because of the wire harness bundle. It seems there is a lot more space under the Z1 tank.

Here is one example of the same type of conversion of a early 1000 engine in a 650 frame showing the oil line routing on a street bike.

Just out of curiosity:
What's your reasons for fitting a 900 or 1000cc engine into a 650cc frame? Is it the technical challenge, or the potential handling advantage of the shorter wheelbase? Or are there no good 900 or 1000cc frames available anymore?

MFP-Joe post=912092 userid=24810Just out of curiosity:
What's your reasons for fitting a 900 or 1000cc engine into a 650cc frame? Is it the technical challenge, or the potential handling advantage of the shorter wheelbase? Or are there no good 900 or 1000cc frames available anymore?

I have never owned a Z1 but I have ridden them quite a few times. I like the torque the engine makes over the 650/750 but the bikes in general sit too high and I feel "small" on them. Even if a 1000 is lowered it is still heavier and physically bigger than a 650. I am only 5' 5" tall so I am more at home on the smaller bikes, a few of my 650's have lowered suspension.

The 650 had always been my preferred street bike but the engine just lacks low end grunt compared to the bigger engines. Even my 831cc 650 is no match to a worked on 1000. The big heavy crank just seems to have the perfect stroke for bigger pistons (over 70mm) and the 650/750 will never be able to replicate that. I have already built bigger version 650/750 engines and the power output is not the same.

I had a spare 1000 engine so I thought this would be my chance to make a torque monster that fits me physically.