Restoring a 1978 KZ 650 ... again ...

It must be my religion - every 20 yrs I get a 1978 KZ650 and give it the Million-Mile-Service.

Last time, it was 1978, and it was a KZ650 B - bought that one for $50 USD (it was in 6 boxes, case split, frame nearly stripped, shims and gears everywhere, bolts infesting the boxes) and spent about $1,100 USD and about 1 1/2 years of my free time on it, but when it was finished, it was one suweet ride.

This time, I got me a 78 KZ650 SR D1 - in much better condition than last time - I actually rode it the 1/2 mile to my house before it died on me. Either the battery, or some part of the charging system is going to need attention.

So far, I have rebuilt the carbs and done the rough sync (more varnish in the carbs than on most boats); dismantled the front end; removed the crunchy material that used to be grease from the spedo assy; disassembled and cleaned the forks (the oil was black as tar, and smelled like rear-end gear oil), replaced the seals, and re-assembled them; removed the front wheel bearings and the steering stem bearings/races (waiting on replacement parts); straightened the fender (bike was laid down at some point); cleaned the airbox, fenders, chainguard, tail light assy, side covers (one needs a prong JB-Welded back on), battery box, and steering head.
The instrument bracket was broken, making the speedometer flop around, so I got that removed and cleaned all the parts that hang off it, I still have to JB-weld it back together.

The only thing I plan to do the the engine as yet is remove the valve cover and check the clearance between the cam and the tappets.

Still much to do on this project (Front Master Cylinder, front tire, points/condensers, ignition coils, ignition switch, carb-to-engine boots, right side electronics pack on the handlebar (kill switch, starter) is broken and needs replaced, seat cover, instrument lightbulbs, inspect rear wheel bearings and swingarm bushings/bearings, right side mirror, clutch cable, speedo cable, tach cable, paint) but at least it keeps me out of trouble!

I've never been a rich man, so I have to go a bit at a time. Glad to see there are many others that appreciate these vintage machines!

P.S. Sorry for no photos, but like I said - poor man. I should prolly get a disposable camera, and scan them in, but I am lazy too .. (might explain the poor - heh!)

Old Timer,

First off welcome aboard... Older farts like us are welcomed and encouraged here. Especially on old school methods and ideas of how to accomplish issues.

Example: We didn't have $$$ or computers back then so with a roll of duct tape and Bailing Wire, hell we could make a sprocket... lol! :laugh:

Sorry for no photos, but like I said - poor man. I should probably get a disposable camera, and scan them in, but I am lazy too

Now if you want to make a whole lot of new friends here, especially with the younger members on what old Dinosaurs like us can do, PHOTO's are a must...

Everyone here loves images... Small digital cameras now days aren't that expensive compared to motorcycle parts!

Old Man Rock

Welcome to KZr OLTIMER.


I haven't hit Geezer status yet (only 43 y/o), oddly enough though I belong to an M/C club called the "Geezers". :huh:
So I guess I'm a Geezer in training? :laugh:


OMR is right, there's a bazzilion diff manufacturers that offer cheapy digital cameras. My bro-in-law bought one of the cheapy kind (included the software to download to a puter plus minor photo editing options) a couple of years ago at Wally World, and IIRC it was only about $20~$30. :woohoo:

I've got a '78 KZ650-D (SR) also.
I had planned on resto-ing it, but it was abused to badly by it's PO.
So it's stripped down in my garage right now and awaiting me to list it all on eBay.
So if there's anything you need for your bike, just shoot me a PM and I'll check to see if I have it.

If you're in need of NOS OEM or aftermarket parts, give Z1 Enterprises.com a look-see.
They've got great prices and service, and the owner (Jeff Saunders) is also a member of KZrider.

I haven't hit Geezer status yet (only 43 y/o),

Meh - I'd better change my username then - you got me by a year, and if you aren't a geezer, that makes me a young pup.
Funny, I don't feel young ...

Wally World, and IIRC it was only about $20~$30.

:ohmy: I better look into that!

So if there's anything you need for your bike, just shoot me a PM and I'll check to see if I have it.

Thanks a ton, I will take you up on that!

In fact, I have a list of the parts I need at my website , with the prices Z1 lists for them.

So, if anyone has any of these, let's talk!

Thanks, gang!

Peace,
-Not-So-Ol'Timer

Well, I went and got me a digicam, so here are some shots of the project. Click thumbnails for larger image:
Left side, with sprocket cover removed

Front Master cylinder, wired up to #4 exhaust to prevent leaking out the ground-off corner:

Front view of bike:

Instrument mount - cleaned, ready for JB-weld then paint:

One of the intakes, note the crack near bolt flange:

Another intake, same type of crack:

Petcock (vacuum-operated). Leaks, I can't find a rebuild kit for it:

Right rear of bike:

Saddle. Another rip is on right rear top seam:

Overall shot of left side:

Tank, taken with flash on:

Tank, taken with flash off:

Top of tranny. What is that cover for?

I have also placed a Mugshot over here .

Top of tranny. What is that cover for?

It's just a breather cover for the engine. There is supposed to be a hose that runs from the hole in the cover to the airbox.

mariozappa wrote:

Top of tranny. What is that cover for?

It's just a breather cover for the engine. There is supposed to be a hose that runs from the hole in the cover to the airbox.

Yeah, I remember I had to take mine apart to see what it was all about. Luckily I was able to put it back together again.

BTW: Good luck with your project!

OLTIMER wrote:

In fact, I have a list of the parts I need at my website , with the prices Z1 lists for them.

Ho boy, if I posted a list like that... :blink: :laugh:
I've made one now and then, just when i want to get real depressed

No pix yet, because I am too busy. Will get to it if I can.

Still have to do:
Ignition Coil (2)
Petcock rebuild
Airbox coil springs
Airbox hoses
Air filter / oil filter / oil change
Footrest dampers
Rectifier / regulator (ouch)
turn signal lens
front tire / tube
possibly battery
and, the parts I am stuck on, numbers 14 and 15 on this parts list 'breather tube' and 'clamp breather pipe'. I tried searching @ Z1, but came up with nothing.
Anyone know where they can be found?
Thx!

welcome to z-jungle!have you checked your coils with a meter to make sure theyre bad?nothing wrong with stock coils if they are good

Do you need an instrument mount? I am not going to use mine from my 78 kz650sr. Send an email if you do.

PLUMMEN wrote:

have you checked your coils with a meter to make sure theyre bad?

Yep. They are both bad, I am replacing them both.

KawiConvert wrote:

Do you need an instrument mount?

Nope. Repaired mine using J-B Weld . Thanks all the same, though!

Still seeking a breather tube - anyone have any ideas where online I could order one?