KZ650 Almost there

Ok, rather than bring out the old thread that I would start a newer one.

Anyways, it has almost been a year since I bought the bike and I am almost done with it. Just a few brackets to coat that I forgot the first time and my side panels to get coated the same color as the frame. Also waiting for my Honda (I know) headlight to arrive so that I can get it all bolted back up. Overall my only real regrets are the excess slope of the seat and not putting knee dents in the tank. Makes the ride a little less comfortable, but I only plan to put about 30 miles on it at a time at max. No real need to go for long cruises on 395, I don't have enough life insurance yet .

I'll update with a new picture when it is done (hopefully this week) and possibly more pictures if I decide to tear back into it again and do some other changes to it. Right now I am going to start saving for the point-less ignition and some new coils.

Figured I would throw in the starting pic in this thread as well. Thanks for all of the help so far, it has been a big help being able to ask questions and talk to others about problems/ideas with the bike.

She's comin along nicely.

What gas tank have you got on there?

1978 Yamaha XS Eleven with a HD cap and bung. Barely clears the controls at full lock, but it doesn't interfere with steering.

Ok, as an update it is up and running again. Still having some carb issues and need to get into the engine a little more, but it does well when warmed up and has provide at least 200 good miles with 200 miles of trouble shooting before that.

Latest changes to it is the addition of a hydraulic clutch that I adapted from a late model Suzuki 1100 and the MC from a ZX7RR. Fits on very well and is also very smooth in use. Swapped mirrors as the Napoleon style emgo ones from Z1 weren't quite the look I was going for. Also, built the headlight mount out of some 1/4" chromed rod and the cheap clamp on headlight mounts I had purchased. Overall, I am happy with where it is at right now. Mainly need to put some time in cleaning and fine tuning the carbs/engine. I haven't had a chance to push the suspension much since changing the shocks back to stock ones, but I am interested to see what has changed with the handling.

Thanks again to those who have helped me to trouble shoot the problems I've run into with this beastly thing. Nothing like my first "completed" project.

Sprocket Cover/Clutch Hose

Controls/Headlight Mount

As a note on the headlight mount, it has the rubber bushings where it attaches to the top triple, other wise it is not buffered. I use H4 bulbs in it and have only had to replace the original one and have had no problems since.

Nice, totally different looking bike... Me likey!

Seems as though the tank already has some knee dents in it's Yamadog design....

Had you relocated the rear sets (hard to tell in the image)?

OMR

How about some details on that clutch conversion? BTW the bike looks good. I also thing the seat needs to pitch a little less. Different to say the least but very good. Nice job.

Nice work.

How about some details on that clutch conversion?

Yes please.
I rode mine the other day, just a short ride, and my clutch hand was already sore.

Old Man Rock wrote:

Nice, totally different looking bike... Me likey!

Seems as though the tank already has some knee dents in it's Yamadog design....

Had you relocated the rear sets (hard to tell in the image)?

OMR

I did the ones where I flipped the mounts and kept the same bolts as stock. Pretty easy to do and only have to watch out when kick-starting the bike.

As for knee dents, they aren't deep enough to be functional as the tank is still a little wide for the seating position. I am trying to get another tank to cut up and work on, but they are still going too high on ebay.

Locozuna wrote:

How about some details on that clutch conversion? BTW the bike looks good. I also thing the seat needs to pitch a little less. Different to say the least but very good. Nice job.

I still haven't found my shop camera since moving, it has pictures of the inside of the clutch. Basically I cut out the inside of the cover, made some standoff/mounts for the slave cylinder, made a plate with spacers to line everything up right, and welded it up. Then I put on the outside cover and welded it on. If I did it again I would have put blanks in for the mounts, welded it up, and then machined it on a CNC, and then put on the cover and welded that into place. But, I did not have access to a CNC when I did this, so for a cut out, weld up, and file-to-fit it worked well.

Thanks also on the bike. I've been trying to get a look to the tank and fender that blended well. And as I've never done this before it is nice when it works out as well as it did. I'll post more on the clutch later.