81 kz650h1 project "test pilot"

I actually went back to the stock air box, decided I'd skip the hassle of fighting with jetting, may play with it after I have ridden it some, the carbs have been cleaned and gone through.

I'm thinking maybe there is an issue with the timing, I removed the cover that goes over the pickup coils, and it is fairly oxidized in there, I'm thinking there may be an issue with the timing advancer. Unfortunely someone has been in there prior to me and stripped the screw heads, was late so I just gave up for the night. I'm hoping to be able to remove the screws with some vice grips, or possibly slot them and try a straight slot screwdriver.

If the pulsing coil plate screws are damaged, use a dremel to cut slots in them so that a screwdriver can be used.

The KZ650-CSR came stock with electronic ignition, so there's nothing to set. What you should do, though, is clean, check & lubricate the timing advancer. check that the springs aren't stretched or damaged or anything. separate the rotor from the advancer body, clean everything, then lubricate the advancer & fill the groove with grease. lubricate the spring ends & pivot points. Reassemble & check that the advancer operates smoothly. hold the body, then turn & release the rotor >> it should snap back. Use a torque wrench to properly torque the advancer bolt. Install a new engine cover gasket.

Important note: Put a 17mm wrench on the big crankshaft nut to keep the crankshaft from turning, then use a 14mm wrench to remove the advancer bolt. You must use both wrenches. Do not turn the crankshaft using the 14mm advancer bolt >> timing advancer damage could occur.
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Any recommended lube for the advancer itself? Or just a light greasing?

This is what it looks like, I dont feel the oxidizing is "normal"

Looks like it's been wet, maybe from sitting outside w a bad gasket. It should be clean in there with only minor oxidation.
I would use a penetrant on the screws. and vibration. heat from a heat gun might help as well.

Timing advancer lube. I use high temp brake & wheel bearing grease. dielectric grease & white lithium grease didn't work. doh.


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See that was my instinct. Spray some white lithium and call it "lubed". I plan to mess with it some this evening, fingers crossed lol

Well this happened

WHAT HAPPENED?

I got it running and noticed fuel running out thr overflows, I thought I had cleaned it all up, went to fire it up and it backfired through the carbs and lit up the air box, cooked the wiring and side panels and airbox before I could get it out, also burnt through the roof of my brother in laws shed I have had it in

HOLY SHT :ohmy:

That bites. Are you going to forge ahead with the project? If so, the 81-83 650-CSR & 80-83 750E/H models used the same airbox. You can probably find a good used wire harness on EB. Replacement side covers for the csr are readily available & if you need the plastic electro cover, that should be easy to find as well. Anyway, sorry to hear about the setback. :blush:



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The project will be moving forward, just a little more in depth now, thanks for the heads up about the airbox, that was my biggest concern, I really dont want to have to play the jetting game.

Of course that happens when I'm about ready to bring it to my buddy's to do the welding and such. Such is life. Time to push forward, the melted plastic should be a treat to clean up lol