Katit's 1978 KZ650 project

There is arrows on mine, pointing forward I assume

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Sorry to say hardrockminer but this screen shot was taken from the first 1976 service manual.

 

Some confusion here.  Z1 and KZ1000 use the same caps.  My Z1 doesn't have arrows.  My KZ1000 does.  Should I post photos?

HRM, the axle caps are different. Z1 uses 44063-003. The kz900/1000 use 44063-014. 

Interesting....I'm pretty sure I used a set of Z1 caps on my rebuild.  Which is why I commented on the lack of letters, thinking others have probably done the same.  I'm currently on vacation but will check when I get back home.  I think the front wheel on a 650 is the same as a 77 KZ1000.

Process. Brake calipers assembled, ready to install.
Bought engine hoist, unfortunately I didn't find any better way to get engine out of a bench. I am planning to lay it on a side and put frame over it. Sounds like it's a best way to approach.

 

I am  planning to lay it on a side and put frame over it. Sounds like it's a best way to approach

Yes I did it that way last winter whit my Z1B. My son and à friend helped me and the job was done in about ten minutes, and no scratches. 

Aaand done. Since nothing was really assembled, I quickly got back to frame. Layed engine on side, prepped hardware. Wife with daughter held frame over and I got it positioned. Then I put it upright, used engine hoist once again to lift by the frame and got rear wheel and forks installed. Back on a lift!! They only "gotcha" - got those wire clamps bent, They probably wasn't correctly installed.

 

Finished painting all plastics, some before/after

P.S. Ordered those stupid rubber washers for forks, still not shipped and it really holding me from getting front end assembly going

 

Need some help here. What are those brackets for? Mount behind rear footpegs. There is no positive stop/orientation on how they should be. Is it for exhaust? 
I get it I need left one for center stand bump stop. What about right one? I am going to use Delkevich 4-1 exhaust

 

Yes, exhaust mount hanger brackets for standard 4 into 2 exhaust. The delkevic 4 into 1 comes with a mount bracket that has a center stand rubber stop on it.
Those oem brackets are quite hard to come by and people restoring to standard pay decent money for them here in the uk. 

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Yes, exhaust mount hanger brackets for standard 4 into 2 exhaust. The delkevic 4 into 1 comes with a mount bracket that has a center stand rubber stop on it.
Those oem brackets are quite hard to come by and people restoring to standard pay decent money for them here in the uk. 

Thank you! Good to know. Since it's "loose" assembly I will leave them on until  get to installing exhaust. One on a right is damaged, specifically clip on a left which retains thin nut. Left one is perfect.

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Blocking the smog ports is pretty easy.  Here is what I used on my KZ750 head.  I used a NPT tap and plug.  It took a few tries to get the depth right for the tapered threads so the plug ended up flush or just below.  I ended up grinding a chamfer on the outer top edge of the plug to help, since it is at an angle to the surface it threads into.
 

 

what size tap and plug did u use?