Z650 REDISCOVERED 24 YEARS LATER

[KWACKERZ1]

Have been making slow progress with the bike due to other jobs but I have cleaned up the engine,

[img][img]http://i223.photobucket.com/albums/dd291/kwackerz1/engineclean.jpg[/img]

And polished cleaned and polished all the spokes and the wheels which took bloody ages, they are still not perfect but will be good enough for this "budget" project.

Also had the Frame and bits and bobs stripped and powder coated,

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[img][img]http://i223.photobucket.com/albums/dd291/kwackerz1/bitscoated.jpg[/img]

So basically I need to get cracking as I have most of the bits ready now.

I have also sourced a 2-4 seat and potentially a marshall 4-1 so I think all I need now is a set of clocks.

I will get there eventually!

[floydsz1]

looking good.

[KWACKERZ1]

Well the 2-4 seat and marshall and clocks never materialised, the bloke from Zcustoms and spares (stockport) promised them at a good price and in the end I gave up leaving mesages for him after three conversations and several chases I got some clocks off e-bay instead.

The bike is still making slow progress but having just taken delivery of some more bits from z-power, I will get on with it. I have started piecing the shiny black bits together and this is where it is now.
[img][img]http://i223.photobucket.com/albums/dd291/kwackerz1/DSCN0673.jpg[/img]
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[img][img]http://i223.photobucket.com/albums/dd291/kwackerz1/DSCN0675.jpg[/img][/img]

[KWACKERZ1]

I am ashamed that its taken me so long to get further
on with this project, its over a year since I bought it back
so I need to get my ar*e in gear and get on with it.

Mothra gave me a reminder recently so since then I have
been awol in the shed a lot.

My problems with the 650 are still the same, trying to do it on a budget and exhausts costs loads of money. (The only stuff available 2nd hand seems to be motads/neyta's both good pipes but a bit on the bulky side.)

Anyway I aquired a really nice stainless Gpz550 system at Stamford hall last year that is made with two 2-1 collector pipes that then do a 2-1 along for the exhaust, so as the piper on the bike was as rotten as a pear i thought I would chance my arm.
So Hacked the down pipes of the piper,



[img][img]http://i223.photobucket.com/albums/dd291/kwackerz1/downpipes.jpg[/img]



And tried them in the GPZ550 system.
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[img][img]http://i223.photobucket.com/albums/dd291/kwackerz1/gpz550tpipe.jpg[/img]
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I have no idea how it will line up till I get the engine in the chassis!
So with that thought in mind the engine.

I love bike restoration it brings so many challenges

So I turn to my original motor with the 717cc kit on it (the one i have spent ages cleaning up and painting) and take the Cam box off to do the shims.
Surprise its a HYVO Cam chain setup!
Originally when I had it it was a roller chain!
So it looks like its a different engine

So now I don't know if it even has the 717cc kit on anymore!
Mind you it compression tests ok on all cylinders!
This engine was also missing the starter motor and alternator so I thought ok go to

Plan B.

The spare motor I bought to take the starter and alternator from I am assured is a good one and its well clean. Its just that its an emission control one,
No problem I thought swap the cam box cover to get rid of this crap!


So stripped off the cam box and the motor inside is:
a) A roller chain one! Yippee!
b) Almost like new and obvioulsy has not been messed with.

So did the shims and thought ok put the std cam box cover on. DOH!
It won't fit , as the emmision engines have different castings in the head,
Emission head!

UK STD HEAD


Normally I strip of all this crap of every bike I have owned but it looks like i'll be keeping this head and just blocking off the pipes!

Unless I strip both good motors swap the heads, check the barrells for the 717. etc etc. But heh at the end of the day its only a budget project so I'll just stick the emission control engine in and run with that.
Oh but now I need a different gasket

These surprises got me thinking though,
When did they change to Hyvo, ? z650 H'S I think, but the engine number on my original motor ties in with a B1 motor not an H
So is it possible to change the cams and crank to convert a B motor to a hyvo chain setup.?

Is this why there is no starter motor because it needs a different starter clutch setup.?

I have asked the dvla for a full history so I can determine if the engine was swapped, as I know the original my 717cc motor was well thrashed when I had it
But as the bike still has the same front tyre for 25 yrs you would sort of assumed it has not done much work?

I have also been painting the bodywork pics from that in a few days, as I am now off to clean up my second engine, ce la vie

[mothra]

Kwackerz1, looks like you are making fast progress... But that emissions control cam cover is hideous.

looking at the Kawasaki parts site:

http://www.kawasaki.com/DefaultFrame.as ... EHTABS%3d1

The Hyvo chains did look like they came in with the H1s, but if correct that must mean that there's loads of potential roller chain cam covers you could pick up on ebay?

Having said that, I'd decided my engine was from an H1 as it had hyvo/Plastic Cam guides - if your engine number starts KZ650DE then it's from an H and not the original B.

Does that help at all?

[KWACKERZ1]

AAARGH
Thats the interesting thing.

1st engine which I thought was original is kz650BE011884, but it has an hyvo chain in it.
But the best infor I can find is

http://models.kz650.info/index.htm which suggests
The engine is a C4 which should be a roller chain!

The second motor KZ650BE095000 Relates to a B3 but its the emission control one.

Unfortunatley you cannot just swap the cam cover as emmision castings in the head would stick out the sides.

SO you would have to change the head. So rather than rip apart a good motor for cosmetic reasons, I will run with the emission sh%t initially.
If it is a good one then maybe I'll make some flat blanking plates to get rid of all the rubbish.

Back to the shed tonight to keep the momentum going!

[Pigford]

I've seen billet blanking plates for the 1000 motors... they might fit.....
Or its "get the files out" time

[compo z1r]

yes indeed good to be re-united with an old friend

would not be good for me i rode my bikes to distruction when a teenager into youth. all knack'ed.

[KWACKERZ1]

I was hiding in the cold shed again last night!
It's funny how cold it is when you first go in there and
once you get started you forget.

Anyway last nights job was to clean the second engine,
so having spent ages on the bench struggling in the end
it had to go in the parts cleaner.

So one hernia later!


And a bit of scrubbing (well a lot actually!)


Its not come up to bad, and I think I'll leave the finish as is,
I hate to see painted ones as its cheating really.
(unless there black anyway)
It did occur to me though how much simpler it would be if you
could afford the Steve SMethurst treatment!

I also cleaned up the mudgaurds I have aquired this week,
the front Although having some slight marks on the top,
underneath it cleaned up mint.
This came from DK through a best offer auction,
I made them an offer a few weeks ago, which
they rejected and then I retried last week and they accepted.
I still think its was expensive but these 650 gaurds
are like gold dust to get.

The rear gaurd is a short US one and underneath
it had been undersealed (badly) and looked rotten
so I was dissappointed with it when it turned up.
Spent ages removing the underseal and treated the surface rust
and now its ok.
Again these things are really difficult to find so I although initially dissapointed I was grateful to be able to get one!

I then treated and hammerighted the underneath of both gaurds
for a bit of extra protection.



As you can see neither are immaculate but they are
serviceable and the right ones!


After that I'd thought I'll finish off the paintwork
as I have been waiting for the laquer to set on the tank
and sidepanel before sanding back and polishing.




I used Farecla rubbing and finishing compound and although expensive it is really good stuff for removing those little marks,
much better than T-Cut.

I am quite pleased with the paintwork,
its not bad for a home amateur job done in the shed with cans,
although it does take bloody ages to the preparation work,
and ages to tidy up afterwards.
Next jobs ;
Engine in frame and sort the wiring!
(After a well deserved trip to the pub tonight!)

[tlc]

Nice one Kwacker.

Have a beer on me

[mothra]

That colour looks brilliant.

Interested to see that front guard - I'd been watching it on ebay, but couldn't justify what they were asking. Glad someone I know got it, presumably for a good price.

Are you going to polish the engine cases?

[KWACKERZ1]

The Front gaurd has a minor scratch which wont come out, a a couple of dinks, and dents so its by no mean immaculate. £50 though hurt a bit but was better than the £69 they had it up for. Also I wanted a 650 one to match the look of when I had it originally. Any more than that I would have just bought a replica brand new 1000 one from z-power. I just hate to see plastic gaurds on std forks, they look ok on modern forks as metal ones are not wide enough, to fit. But Chrome for me on std stuff!

[Ginger Bear]

KWACKERZ1,

That is looking GOOD

I, think it would be fantastic to have some sort of register on here, of Zed's that have been previously owned + the date's they were owned.
Hopefully, those nice 'site administrator' people could look into it

Those wheels have come up a treat, I just need to know are you planning to keep those 25 year old tyres on ''for old time's sake'' :?:

[KWACKERZ1]

Thanks Ginger,

The tyres will have to go! I have had enough accidents due to dodgy rubber to risk it.

But I can't wait to see my mate at the tyre fitters getting this one off!

[mikey]

Like the paint job you done looks very good for a home effort like the color as well, goes to show all kawasakis dont have to be green, think i may get some flak for that.