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Saving a '81 KZ750-E 30 Jul 2021 13:50 #852865

  • Skidmark
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I am using Wood Craft clip ons.  There is no room on either bar to clamp anything else.  I will bypass the wiring used for the hazard flasher circuits.
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'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker

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Saving a '81 KZ750-E 30 Jul 2021 16:05 #852872

  • Nessism
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My '81 750E uses the later type hand controls.  Pretty sure there is a hazard switch and the feature to alert the rider when one of the headlamp filaments burns out.

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Saving a '81 KZ750-E 30 Jul 2021 16:36 #852873

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I know the original controls had the hazard switch.  The new repops are for a Z1, and do not have that switch.  Thus I won't be using the hazard switch wires in the harness.  The wiring diagram for my bike is starting to piss me off.  I am finding connectors not in the diagram.  I didn't think getting the electrical sorted would be this much of a headache.  Did I day I hate wiring?  Well, I hate wiring... 
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'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker

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Saving a '81 KZ750-E 30 Jul 2021 16:55 #852874

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I found this connector, and the diagram lists it for a "warning light self checker".  It is coming out of the rear loom on the right side near the battery.  Is this for a factory diagnostic tool to plug into?  I can't find anything that has the same shape connector on the bike.
 
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'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker
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Saving a '81 KZ750-E 30 Jul 2021 17:22 #852878

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The warning light self checker connector need the same electronic divice like the rear break failure "idiot light" 

 
 
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Saving a '81 KZ750-E 01 Aug 2021 14:15 #852990

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I ended up finding my warning light self checker.  I seem to spend the majority of my time looking for parts or fasteners to put this bike together.  I was "okay" at bagging and tagging everything, or so I thought.  Turns out I am only so-so at that task.  Note taken for the next project!

I finally got my left handlebar control all sorted and hooked up.  Once the battery is hooked up and the ignition turned on, I will test it out.  But for now, all the connections make sense to me.  Now on the the right handlebar controls...

I received some of my spark plug wire parts.  I am building my own wires.  I got NGK resistor spark plug caps, and the coil ends.  Hopefully my bulk wire will be here in a few days.  I still need oil to put in the crankcase.  Hopefully this thing wire fire up for the first time in the next week.  Not drivable, but will be able to hear the motor for the first time.  It' going to be a milestone moment on this project!
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'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker

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Saving a '81 KZ750-E 03 Aug 2021 10:20 #853075

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As I draw near to firing up the motor, my intention was to turn the engine over without the spark plugs in, to get oil pressure before applying any spark or fuel.  I was thinking about using an impact gun on the right end of the crank.  In my mind this shouldn't have any issues or risks.  How long should the oil pump take to circulate oil throughout the motor and top end at low RPM?  30 seconds? 1 or 2 minutes?  5 minutes?  I used assembly lube during the rebuild, so is this overkill?  I'm not sure I trust the oil pressure light when it comes to getting oil throughout the top end.  I would love to hear some opinions on this.
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'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker

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Saving a '81 KZ750-E 03 Aug 2021 14:08 #853092

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An impact gun is not the best idea, you can shere off the bolt or location pin on the crank.
Use the starter motor until the oil pressure light gets off + 5 seconds to pump up oil to the camshaft bearings.
Repeat the the sequence 2 times and you are ready to fire up the engine, a short first start video would be nice
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Saving a '81 KZ750-E 03 Aug 2021 15:31 #853097

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Last time I did this I took the plugs out and just pushed the bike along the driveway in 2nd. Figured this would be easier on the 'dry' parts than turning it over with the starter.
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Saving a '81 KZ750-E 03 Aug 2021 21:48 #853125

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I made a new ground strap from the battery to the engine.  One part I spent a lot of time searching for before I threw in the towel and made my own.
 
 

I  also finished wiring up the ignition coils.  Dynatek coils require a different connector than the stock.
 
 

The heat keeps me out of the shop in the afternoons.  Doesn't seem like much progress, but got to keep pushing forward.
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'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker
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Saving a '81 KZ750-E 04 Aug 2021 13:20 #853155

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I finished making up the spark plug wires.
 
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'81 KZ-750 E2
'87 Suzuki Savage 650 Street Tracker
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Saving a '81 KZ750-E 04 Aug 2021 13:55 #853156

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nice work!

What wires and caps are you using?
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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