77 650-B1 to 79 650-D3 Frame Swap Project

Kawickrice wrote:

PLUMMEN wrote:

remember to lay motor on its side then drop frame down over it to install,much easier.

Is that really easier? I usually put a milk crate or bucket next to it then straddle the frame and manhandle it. That is how I have always done the 900. If it is the easier way I might try it. What is the dead weight difference between the 900 vs the 650, the 650 seems like childs play compared to the 900. But I guess age will dictate this one.

much easier in my experiance ,removing exhuast studs before hand also helps

I found both those gauges for you. Will keep my eyes open for some pegs for you. I've got a couple of D frames in my garage, not sure if there are pegs on them though... If I don't have them I'll ask around and see if I can't come up with some for you.

anarki650 wrote:

I found both those gauges for you. Will keep my eyes open for some pegs for you. I've got a couple of D frames in my garage, not sure if there are pegs on them though... If I don't have them I'll ask around and see if I can't come up with some for you.

I did not forget about you. I will get up with you soon. Still making a list.

What is the easy way to get the fork lock cylinder out without destroying it?

Kawickrice wrote:

What is the easy way to get the fork lock cylinder out without destroying it?

On Z1 and KZ900, it's held in position with a small set screw (maybe allen head type).

Vaguely recall the set screw being accessible when handlebars are turned opposite of "lock" position.

Good Luck!

That would make sense to me but I see nothing as far as a set screw on the 650 frame

did you get the footpegs yet or do i have to go look in the garage to see if i saved them?

kawsakiman wrote:

did you get the footpegs yet or do i have to go look in the garage to see if i saved them?

No I still do not have footpegs. Do you think you still have them?

I have made a little progress in the past few days. I had to put a water pump on my Dodge truck in between working on the bike. Right now I am in the cleaning and degunking stages which takes time, is greasy, and the progress is not showing yet, but will be soon.

The motor is out of the frame and ready for some attention






This is a bag of soda I bought at Harbour Freight for blasting the motor and misc parts. 50# bag of Arm and Hammer baking soda



Here is my blasting equipment I will be using, sand for the frame and the steel parts and baking soda for the aluminum, I will also be polishing the motor covers,fork legs etc.

i'll look as soon as i can for you.
i knew i was giving that frame to a member who would go balls out to get his bike done.
i'm happy to see you making progress.
btw, i got the card today.thanks!

looking forward to more pictures of your build.

The body work is in great shape so a cleaning is all that is needed. My tank is in a little worse shape, my ex wife beat some big dents in it with a big stick that I will be trying the heatgun and cold co2 to pop it back the best I can. (I am glad I got rid of the bitch I only wish I would have done it sooner.




Here is the rear rim before polishing. Its in rough shape but will clean up nice

While I was waiting for the tapered roller bearings to arrive from Z1 Enterprises I had some time for a little polishing and cleaning. The purpose of this project is to get the bike clean and road worthy, It is not a build but rather a swap of parts so the polishing will not be "Show Quality" but rather a cleaning with some attention.


Any project needs to have some tunes but polishing it is mandatory because polishing is boring and tedious.




This is what I have been using to do the polishing. I do not have a polisher that resembles a bench grinder with extended shafts. With a little elbow grease and patience it works nice



Here is the fork legs. One has been polished and the other is what they looked like when I started



This is the fork tube and rear brake. Not a bad reflection for the time spent




This is how far I have gone with some more to go.