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J-Rods 78 KZ650 Build

33K views 108 replies 29 participants last post by  ultimate fighter  
#1 ·
I thought I should start a build thread to show some progress this far. I bought a 78 kz650 about 3 weeks ago as a basket case for $125. The engine had the head and pan off, but the guy assured me all of the parts are there!
Should have said most of the parts are there. Long story short, after 2 weeks of scouring the want adds, I found another basket case engine for $100, it had the starter shaft out as it was NFG, so I was told. Engine arrived greasy, full of dog hair and missing all of the side covers. No problem I have two engines I am bound to make 1 good one.
Here is the first engine, clean but as I found full of rust.


Here is engine 2 upon arrival

and of course a box o parts to go with it. But they were all there and I managed to assemble and clean it up some. After a rattle can of semi-gloss black and a little elbow grease I now have this.



On to the frame and tank. Here it is in my shop after a little sanding to see just how much paint is on this old girl.

It seems like quite a bit, but we'll take care of that later. I have since stripped the frame completely and have proceeded to cut the center stand and passenger peg doohickeys off. I am going to look at this donor bike tonight and will post some more pics tomorrow.



I look forward to your comments, good bad or indifferent. Be honest I have broad shoulders I can take the weight!
 
#4 ·
Not much happened last night, another rattle can of paint on the engine. I bolted the other engine halves and head together for mock up. Much lighter with no internals!. Sealed the deal on the donor bike, it gets here Saturday. I snapped some pics of the frame with another tank I had lying around, not sure if I like it or not.


 
#7 ·
Well not much progress last night, but I did manage to spend a couple of hours on the polishing wheel. I seem to have this condition called polishatitis, I see aluminum and find the need to polish it. Must just be the Ol Skool rodder in my blood. Here are a few pics.
Before



After, still needs some more, but I got bored.


Can't wait til my donor gets here to do some fabbin' Stuck the mock up motor in the frame to check a few things and realized I am missing a bunch of mount bolts, off to the bolt supply I guess.
 
#8 ·
Well made some progress this weekend. Parts bike arrived late Saturday. Here she is in my shop.

and 1 hour later it was down to the bare frame. The bike basically had everything except engine, handlebars and fairing. I docked the rear of the frame and mocked the front on. The dam stem has the same size bearings as the kz but is about 3/8" short.


I bought myself a press and a separated the triples from the stems. I can't use the kz stem in the sv triple, diameter is too small, but I might be able to machine the sv stem enough to get it to work. The swinger looks like it should fit without too much trouble. Just need to shave about 1/8" off each side and get some new bushings made for the kz axle. the shock mount will be the biggest challenge. I am not sure where to even start with this one.
 
#12 ·
Quality work bro! Whats your secret on the engine cleaning/painting? Looked amazing in the pics
 
#13 ·
Thanks for all the positive comments. Not much happened lately, it's been busy at work.
LJWalter78, what I used on the engine was a healthy dose of Castrol Super Clean, let it sit for about 10 mins, brushed around and pressure washed with Hot water. Step two was this nasty stuff.

They use it for cleaning trailers. It says to dilute it, but I used it full strength to get all the corrosion of of the engine, then just wash off. Glasses and gloves a must! Let it dry and sprayed with a rattle can of Dupli-Color low gloss black high heat engine paint. I have used quite a bit of this paint in past projects. it goes on super easy and is quite durable. I used it to paint the complete engine bay and interior of a '35 Ford truck I did for my Dad. I always keep a can on hand.
 
#14 ·
Man i'm jealous. If I had the cash I was eyeing up that donor bike.
 
#15 ·
Sorry boys, haven't had much time to work on the bike. Work is busy and I am heading on a little Vaca next week so won't be much progress until I get back. I did however get my grips in the mail and I dropped my stem and swinger bushings off at the machine shop. They should be finished when I get back, so no more excuses! Check out the grips, keep in mind I am thinking of a green and white paint scheme. These babies are NOS Italian Grand Turismo from the late '60's I love vintage shit.
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#16 ·
Trailer cleaner. I will pick some up for sure. Let me guess, in the home improvement department @ every Walmart?!!! hahaha....
 
#17 ·
Well I am well rested from a week at the beach. Managed to sober up and get a few things accomplished in the last few days. Cleaned up the frame, ready to start bracing and shock mounts. Buttoned up the motor, added oil, compression test (dry) 130, 130 , 150, 120. Not bad but should clean up once I get this pig running.

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There was a ton of carbon that seems to be chunking off and looks like it is getting stuck in the valves. Ordered a set of pod filters from china, should be here in about 2 weeks, still nothing back from the machine shop. Fab'd up a breather out of some old rod parts I had in a box.

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I was trying to get the speedo/tach off of the sv to work on this bike but after all of kaos's hard work on getting me a solution for the tach I chickened out and ended up selling it. Got a good buck for it though. So I am undecided on which speedo to buy.
This is my first choice but a bit pricy for my tight wallet. I like because it is small and I am thinking on mounting it in the tank or in the headlight. Compatibility shouldn't be an issue either.

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This one is cheaper, but bigger and not as streamlined.
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Any other suggestions?
 
#19 ·
Agreed, I will order the round speedo today. I picked up my parts from the machine shop last night, managed to get the forks on. Took Endo's advice and used the KZ stem bushed and welded into the sv triple. Worked out great, the guys did a great job on the machining, fit like a finger in an asshole, nice and tight! As for the rear they messed up my dimensions and my spacer is 6mm too big, still can't fit the swinger in the frame. I am dropping it back off as soon as I finish this post, hopefully they can face it down today. The all balls bearing kit installed easy, front end is good and solid now. Here she is

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I have this headlight from a 30's car I am thinking of using on the bike. I will install the round speedo in the back of it like the old honda's etc. probably put the ignition in there too. Bucket is nice and big to hide wiring. Kind of reminds me of the 40's military Royal Enfield's

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If I get all the parts today it will be late night, time for the parts run.:100SPIN:
 
#20 ·
It has been a few late nights but here is the progress. Swinger is on!!!!! fits like a glove. lower Shock mount tacked on. Headlight mount fab'd and headlight is on!
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Slapping things on for ideas:
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Ordered the speedo on Friday, I went to Danmoto's website and managed to get the same speedo $20 cheaper than E-Bay. Also got a 4-1 header and exhaust off of E-bay on its way. I should have all I need need now, time to finish the puzzle.
 
#22 ·
looks good.
 
#23 ·
Holt, The tank is spoken for at the moment, the guy is supposed to pick it on Mar 3, if he flakes on me I'll let you know. I forgot to post a pic of the nasty weather we have been having here, had to cut myself a path to the workshop before I could do any work last night. We got this in 24 hrs. The back yard was all grass on Friday morning
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#24 ·
Back in the shop last night and looky what I did, She is standing in her own! It's a proud day.
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Notice anything in the picture UF? That's how we roll up in Canada, none of that girly sissy shit!:D

Slapped the SV sub and tail on for kicks, What do you think? Shock mount will need a couple of braces back up to the frame, but I want get the sub mounted first. I am leaning towards using the sub frame and making my own tail to match the lines of the tank.

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And without the tail, I found the light digging through a box of junk at my Dad's Shop, probably off a Harley

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