$400 - 79' KZ650 Restoration and adding a Hack...

I got a bunch of stuff finished since my last post.

Forks:

When changing fork oil Warning Contents under pressure...

Removed the drain plug from my left front fork today. Vile smelly oil shot 6 ft across the room and all over my leg and foot.. WTF....:blink: Quite a bit of oil also..

The right fork behaved better, not shooting a mad stream.

Too refill the tubes I used my head to ensure domestic tranquility.. Took the wifes measuring cup and measured out 5.6oz of water in an empty Coke bottle, marking the level with a Sharpie and used that to measure my refill levels.

Brakes

Pulled apart the right front brake caliper. Looked as if water had got to is and there was a bit of corrosion on the ring that holds the boot on. This corrosion had contaminated the piston and the seal so I think the good cleaning I did will restore things back to normal. Coated the boot ring with some marine grease and I hope that prevent any further incidents.

Replaced my front brake lines and started the bleeding process as well.

It appears the spare master cylinder I got with the bike is defective as the top leaks, so I will keep on with the round top one.. It has 5/8 cast on the bottom so I think I am OK. Still need a new brake lever though.

Paint

Finished my rattle can paint job.. Looks decent but not spectacular by any means. Reinstalled the front fender after doing my brakes, the end of the major work for this project is in sight. Will put the tank back on and try to get some pictures Monday. Maybe even make a test run.

I am waiting on my new Petcock setup from Z1 to arrive, can't wait to get this thing on the road and down to the muffler shop.

Heyo,,, took some pictures today..

I still have some tweaking to do to the gauges, installation of my new Petcock and bleeding of the brakes. Hopefully it will run like a champ.

If not I will have to probably pull the carbs and adjust them as well as do a compression test.

Also did some goofing around with the camera made my first ever video... Enjoy the poor production quality...

This is an awsome build, i like it alot. The royal enfield sounds awsome also.

Thanks for stopping in, I enjoy this type of thing and find that sharing helps the proccess along. Sometimes it helps to write about my issues and I solve em before I finish typing.

OK on to today's progress. Replaced the much hated junk Petcock with a unit from Z1 today and I am very happy to report that the majority of my problems look like the stem from that old petcock.

Cleaned out the tank, I thought I could hear rust rattling around in there.. It turned out to be white chunks of the material lining my tank, probably a previous owner doing some work to preserve the tank. :huh:

I have to do some work on the chain as it is very loose (touching the center stand) and needs lube. I will probably replace it and the sprockets before our road trip. I have to count my teeth so I know what I want.

One thing I noticed on my ride it that the bike likes to be revved over 3.5k to get smooth low speed power with a lot of clutch to get going. It does not have the low end torque I am used to with my 500cc thumper. This could also be because of the tuning and gear ratios on the drive chain.

Any input on how this machine is should perform would be appreciated.

I Think the lack of low end tourqe is due to the bad chain and sprocket. I have a 77 kz 650b and it has good low end tourqe. After you replace the chain and sprockets i think you will be pleasently suprised. How loose is the chain? Can it be adjusted anymore? Ore is it at the end of the adjusters on the swingarm?

Next to your single cylinder bike the 650 will seem weak at low revs. These motors are meant to turn, try shifting at 4,500 or 5,000. Now if the bike seems to hesitate when you roll on the throttle, or sputters, or dogs at high speeds that could be a tuning issue. If your bike dosen't run smoothly and idle reliably then I would be concerned. The spark plugs are also a good indicator of the fuel mixture. Not a bad idea to have a look at your point gaps as well.


If you discover the bike is running lean your exhaust mod may fix that problem somewhat. Bottom line, the 650 should run circles around the Enfield.

I think part of the problem is me in that I am used to running the lower revs of the RE as opposed to what the KZ probably likes. That coupled with I have not had brakes so I really am hesitant to wind it out at all.

Took the bike down to the Muffler shop this morning and the front brakes have finally firmed up to the point they actually work well. I guess it just takes patience to bleed them, as they burp and get a little better every day.

I have about 1/4 of the adjustment remaining on my chain and will adjust and lube it as well as perform oil & filter change after work today. Then I plan on taking the beast out for a nice high speed shakedown as I have not had it over 35mph yet or run it for over 15 minutes.


4 hours and 45 minutes till I am off work... Not that I am counting.......

Well, my machine has a nice new tractor muffler installed. Its pretty quiet compared to the no muffler setup before.

Took it out on the road after an oil change and chain adjust and lube. The oil was a nice dark tan leather color and the old filter was filthy, probably due to sitting for a year or so without running. Glad I changed it.

My chain actually was not that loose, upon closer examination it is rubbing on the center stand but the slack is within limits after a slight adjustment. I think the stand might be missing a grommet or something.

I am getting used to starting off with the higher revs and the way the clutch works.

Its nice and quiet and I do not have trouble until I wind it up past 4k rpm in 4th or 5th gear.. It seems to get winded and not want to go much faster. Can't seem to get it past 65 to 70 mph. I imagine its a jetting issue and I will have to pull my carbs.. Any suggestions on what to do? At the moment I don't even know what jets I am running.

I was at first thinking it might be the new muffler restricting the exhaust but I can rev it up to 7k in lower gears so that leads me to think its a lack of fuel/power and not exhaust restriction.

I know I have to check points gap and condition and plug gap and condition before pulling the carbs as well.

Of note is the fact that the muffler might just be in the way of my hack subframe and need to be moved.. I will be working on the subframe next week. Gotta run down materials (tubing and clamps to attach it to the bike). I think I can get my muffle guy to weld it up for me, so things are moving along nicely.

I will get some pictures Thursday as its raining out now and not the best photo weather.. Might even get a video of the KZ running to demo the muffler.

Love the search function... this post might help me out..

kzrider.com/index.php?option=com_kunena&...d=3&id=295032#296126

Crap... I just lost a very long write-up of how I found out my #3 and #4 carbs were swapped when the PO rebuilt em..:blink:

Well swapped em back and the bike runs fine now, raining though so no real test drive with 4 running cylinders yet..

Found a really good welding shop to build my hack subframe... Looking forward to getting it put on next week...

Oh, anyone have a quick fix for sagging foot pegs?

My rubber is in good shape but it seems as if the pegs are bent down or worn.. Its not the rubber grommets as I have fiddled with em and the angle at the grommets and bolts seem correct, It just seems the pegs are pivoting a bit too far on their pins..

Well,, took a nice weekend off. Will get back to work on the rig Tuesday.

Friday night I got home from work and we had a nice break in the rain so the wife and I took a spin on the KZ to give it a try on 4 cylinders. Man this thing can go if you give it revs. Very nice.

Its idling a bit rough so I have made the home made syncing rig and will give that a try. I am also concerned that the Jets appear to be 97.5s? Seems a bit lean to me..

Got a picture of the tractor (Farmall) muffler on the bike. It looks good but upon measuring it will be in the way of my sidecar Sub frame. I am thinking of removing the center stand and bending the pipe out the left side of the machine.

Took a video of the way it sounds.. Fairly good... I wonder about engine noise but am not sure what a good KZ sounds like..

Garbone What part of Central Florida you from? Im in Tampa.