TOPIC:

I'v just don up the clucth on the z650 hibrid, new cable, cleaned and greesed the cable tranfer race, and also repaced the dampener rubbers in the clutch basket. Big job that one.
I'v decided to go back to the oringinal KZ650 clutch cover on the GPZ bottom end. No problem, all i'v got to do is plug the old kick start hole.
Do i just stick a made up shaft with flange into the hole from outside or inside using the same shaft seal
or take the seal out and press an interference plug with a flange straight in.
any idears

cover almost completed recantly

I thought I saw an aftermarket plug made up to block off the kicker shaft hole but I can't remember where I saw it.

My question is since you are running a GPZ bottom end can you tell me if the GPZ 750 bottom end has the hole machined in the cases to use the 650 clutch pushrod set up? I have a 750 GPZ engine that I want to swap into a 79 KZ 650 B the GPZ engine uses the clutch setup on the cover. I need to know if it is possible to just use the 650 covers and pushrod or do I need to use the GPZ clutch set up?

Not trying to hijack your thread but I figure you might have the answer having already done this swap.

ape sells a kit for 900-1000 im not sure about 650 though;)

If it were me, I'd just use a clutch cover from a newer ('80~) KZ650 like the CSR or LTD that didn't have a kickstarter. I see them on eBay all the time, some even chromed!
That way you can eliminate the hassle of trying to fab some kind of plug to fill the kickstarter hole (which IMHO would probably look really crappy against a freshly polished/chromed cover), and not have to worry if that plug will ever leak.

That's just me though. I'm kind of lazy like that.

RetroRiceRocketRider wrote:

If it were me, I'd just use a clutch cover from a newer ('80~) KZ650 like the CSR or LTD that didn't have a kickstarter. I see them on eBay all the time, some even chromed!
That way you can eliminate the hassle of trying to fab some kind of plug to fill the kickstarter hole (which IMHO would probably look really crappy against a freshly polished/chromed cover), and not have to worry if that plug will ever leak.

That's just me though. I'm kind of lazy like that.

Yeah but keep in mind where he is located, the shipping costs would be huge.

Ape must be where I saw that plug, they should be the same between the 1000 and 650.

wireman wrote:

ape sells a kit for 900-1000 im not sure about 650 though;)

thanks wirman, do u know how there held into the hole?
theres no problem with me making the plug, its just what design i use
I have plenty of 7 series aircraft aloy available

The Gringo wrote:

My question is since you are running a GPZ bottom end can you tell me if the GPZ 750 bottom end has the hole machined in the cases to use the 650 clutch pushrod set up?
Not trying to hijack your thread but I figure you might have the answer having already done this swap.

It all started with me wanting to have a rubber mounted bottom end, hense the gpz750 crank cases with paint removed. Then I still wanted the look of the bike to be like a kz650 trying to look like a z1900. sounds a bit weard but that was the plan
So I'v got the original drive sproket cover and now the original clutch cover
I have to go to work now but will reply later re how to do the selector cover conversion

I'm curious to know how the hell you got that high luster shine on that cover !!!!

My KZ650 covers were pretty crappy looking when I got my bike. I used good ole mother's aluminum polish and patience and they have developed a really nice shine to them. I really like the mother's aluminum polish. Removes crude from just about ANY none chrome surface. I've used it on fork tubes, carb bowls and tops and engine covers. It will clean up the casings and heads but doesn't really make them shiny. That's my $0.02

Peace out all!!!

geerbangr wrote:

I'm curious to know how the hell you got that high luster shine on that cover !!!!

I first filed all the gougers and heavy scratches out with varies files. Then emery cloth or glass paper from a 250 grade all over, that then shows up all of the smaller imperfections so then a little more filling and finish with 400, 600, 1200 grade wet sandin paper. The final finish in done on a buffing wheel on the bench grinder, using white stick polish for aluminium.
Once you take to a cover with a file there's no turning back. That cover did,nt look too bad before i started, then appox 4 hours work with 30 years experiance in metal trades but its the only way of getting that finish

The Gringo wrote:

can you tell me if the GPZ 750 bottom end has the hole machined in the cases to use the 650 clutch pushrod set up? I have a 750 GPZ engine that I want to swap into a 79 KZ 650 B the GPZ engine uses the clutch setup on the cover. I need to know if it is possible to just use the 650 covers and pushrod or do I need to use the GPZ clutch set up?

kawasaki decided to release a shaftdrive model z750GT in the early 80s. To do that they reshaped the crankcases at the point of the gear selector cover mating surfaces larger, to accomadate the bevel gears and shaft drive cover. the bolt holes stayed the same That became the new shape for chain drive models as well
So I added the extra meat through alloy welding to the z650 cover to match the new mating surfaces
Another way would be to add the hole and seal for the push shaft to the gpz cover. You could do that by building up weld to that area on the insideof the cover and then machine the cover to fit the seal, and to get the exact centre point to machine u would have to make a say 2" shaft the smae dia as the original with a point machined at one end then bolt the welded cover on then using the clutch push rod tap through the gear shaft to the pointed shaft to mark the referance point