dragstripkz78 wrote: I am new to this forum and to bike building, I have had 29 motorcycles the past five years.
Welcome to the forum. That is a lot of bikes!
dragstripkz78 wrote: Question #1. can I go with kick start only to simplify the wiring and will that be a bad idea?..
The 77 KZ650 motors use a field coil alternator. That type requires the use of a battery, however, you can use a really tiny 12v battery from a scooter etc. if you want to go kick-only.
Because the 77 is different from all of the other 650's, you need a regulator (or regulator/rectifier combo) designed to work on that type of alternator. Oregonmotorcycleparts.com has them.
Or you may be able to swap in an alternator from a later, 78 or 79, or maybe even later 3-phase KZ650. Then you can go without a battery, but you will need a capacitor as a "battery eliminator".
dragstripkz78 wrote: question #2. will the head light work with out a battery once the bike is running?
Not sure, but the bike won't start without a battery, even with kick starting, unless you change the alternator to a later type.
If you change the alternator, and go batteryless, it won't start with the lights on. You have to give it a little rev, and then turn on the lights.
dragstripkz78 wrote: Question #3. he put pods filters on it, burnt up a piston, it has been totally rebuilt still pods on it. what jets would I use to not have the same problem occur. ..
It was likely something other than simply having pods that caused the piston to burn up, otherwise all four would have burned up. But with pods, you will definitely have to use something other than stock jetting. Increase the main, and the pilot, and raise the needle one notch.
