kz 650 into 440 swap

Hey guys,

This is my first post on the forum so I'm sorry if its in the wrong category.

I have an 81 KZ 440, and came across a guy that has an 81 KZ 650. The 650 is complete, but the outer appearance is in pretty rough shape. My question is if I can use the engine, transmission, etc along with the mint condition parts from my 440 to make one complete 650. What is the best way to do this without breaking my wallet? I've been told that Kawasaki made each frame different according to the size of the engine. Any help you guys can offer will be greatly appreciated.

That's not even close to being a feasable swap. You would be better off selling the 440 and putting the money towards making the 650 nice again. JMHO.

I once put a BSA 500 (A50) twin engine in a BSA 350 single (B40) frame; but it wasn't easy. I'm betting that putting a 650 4-cylinder engine in a 440 twin frame would REALLY be tough. Plus, will the 440 frame, brakes, etc. handle the additional power & weight when you're done? Ed

The Gringo wrote:

That's not even close to being a feasable swap. You would be better off selling the 440 and putting the money towards making the 650 nice again. JMHO.

i back that. let's see pictures of both.

I'm being told by the Kawi dealers here that many of the parts are no longer available for the 650. Any websites you know of that carry parts for these bikes?

The dealership wants to sell you a new bike.
Old bikes don't generate as much revenue & can be a pain to work on for the tech who's on the clock.

Z1Enterprises.com has parts & maintenance items for your bike. K&L parts are made in Japan & OEM quality. Also, they can get just about anything that the dealer can - some stuff is still available. Reference the diagrams at Kawasaki.com - click stuff - anything listed as Active is most likely available. Ebbaayy is a good source for parts - used, new & NOS (new old stock).

What parts do you need?

I need to rebuild the carbs, whoever was in there last really did a hack job on them. I still need to go through wiring for the ignition. I think most of the major components will be ok. I need a lot of the small external parts, such as the speedo cluster, turning lights, exhaust, side covers. I'm working on getting the bike to start and run, at this point it shows no signs of life. I'll post some pictures in a couple days of both.

First off, I own both a 650 and a 440, and it would take way too much work to shoe horn a 650 4 cylinder into that frame, plus you wouldn't save enough weight to get any benefit out of doing it. Nah I'm with everyone else, don't do it.


Second, the KZ650 is one of the best vinatge Kaws to restore. There are still a good supply of Factory Kawasaki parts, good used parts, and lots of aftermarket parts. The bigger fours (900 and 1100's) can get spendy to rebuild, 650's are cheaper to buy, cheaper to fix, and cheaper to overhaul. But I do think in years to come the bigger bikes will be worth some serious coin.

I started with a bike the was "cafe-ed" with no gauges, cut up wiring and clip on bars. I converted it back to a factory look with boneyard parts and stuff from e-bay. Sounds like you are in the same boat. Its not that expensive if you have some patience when looking for parts.

You have three otpoins for carbs, overhaul them yourself ($75), send them to Wierd George for overhaul($350), or buy a different set($25-$75).

I have some parts: controls, bars, and a complete wiring harness if you are interested send me a PM.

Here is my rebuild in progress...

kzrider.com/index.php?option=com_kunena&...w&catid=11&id=214272

I cleaned the carbs and re-installed them, cleaned the whole bike up with some elbow grease and detailed the metal pretty good. I found the source of my wiring problems...spark plug caps were shot, the ignition key switch was not wired up, the starter wires were corroded, as well as the positive battery cable was cut. the bike runs well enough to ride. I took it to work today, and my co worker offered me 700 cash to buy it as it is. I also just picked up a KZ 750, in about the same condition. I appreciate all your help on the 650. I hope you'll offer me up the same help on the 750 as well.

engine wise almost identical bike what works for one will on the other.

meathead wrote:

I cleaned the carbs and re-installed them, cleaned the whole bike up with some elbow grease and detailed the metal pretty good. I found the source of my wiring problems...spark plug caps were shot, the ignition key switch was not wired up, the starter wires were corroded, as well as the positive battery cable was cut. the bike runs well enough to ride. I took it to work today, and my co worker offered me 700 cash to buy it as it is. I also just picked up a KZ 750, in about the same condition. I appreciate all your help on the 650. I hope you'll offer me up the same help on the 750 as well.

That's it? Come on, you have lots more questions. Just got it running, now need to fine tune it and start working on the cosmetics. We'll wait right here for next question....:laugh: