REVscene Automotive Forum - 320icar's '77 kawasaki kz650 project

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320icar's '77 kawasaki kz650 project

coles notes

- new project, 1977 kawasaki kz650
- stripped down to bare frame, time to cut, weld, clean, modify, and get working

my gf and i have multiple bikes, and this is my second sort of older bike project. the first one was a little 1cyl 100cc 2 stroke that i pretty much disassembled, spruced up and put back together. this next project is going to be much more involved

Spoiler!

- much bigger aspirations for this bike
- picked up a honda vfr single sided swing arm
- pictures should say the rest so far...

https://c6.staticflickr.com/8/7686/2...9d4a3921_c.jpg Untitled by 320iCar, on Flickr

https://c1.staticflickr.com/9/8701/2...61ed3f15_c.jpg Untitled by 320iCar, on Flickr

https://c7.staticflickr.com/9/8846/2...322fbc8d_c.jpg Untitled by 320iCar, on Flickr

https://c3.staticflickr.com/9/8704/2...cbb1abfd_c.jpg Untitled by 320iCar, on Flickr

https://c7.staticflickr.com/9/8340/2...6fa9f342_c.jpg Untitled by 320iCar, on Flickr

https://c1.staticflickr.com/9/8232/2...e6cd6bd8_c.jpg Untitled by 320iCar, on Flickr

https://c3.staticflickr.com/9/8606/2...666157af_c.jpg Untitled by 320iCar, on Flickr

https://c3.staticflickr.com/9/8408/2...82fce1ce_c.jpg Untitled by 320iCar, on Flickr

starting hammering the tank to make some knee dents. aaaaand of course it completely fucks up and kinks. the tank looked and felt perfect prior to my hammering. so i stripped off al the paint and there was imperial ton of bondo underneath the paint. my idea was fucked from the get-go. not quite sure what to do with this tank now. i guess leave it raw and maybe rusty, and source a new one down the road. picutres show after i already chipped and stripped off most of the bondo.

https://c2.staticflickr.com/8/7482/2...9db18850_c.jpg Untitled by 320iCar, on Flickr

https://c3.staticflickr.com/9/8087/2...489e12dc_c.jpg Untitled by 320iCar, on Flickr

https://c5.staticflickr.com/9/8706/2...edcf88d1_c.jpg Untitled by 320iCar, on Flickr

https://c4.staticflickr.com/9/8695/2...ea0b83a2_c.jpg Untitled by 320iCar, on Flickr

engine is pretty much ready, sans electrical, vacuum and fuel lines

https://c3.staticflickr.com/9/8829/2...a3ab4d43_c.jpg Untitled by 320iCar, on Flickr

and picked up some more parts. another vfr swingarm with different wheel, and a k6 gsxr 600 front end

https://c3.staticflickr.com/9/8854/2...5e344874_c.jpg Untitled by 320iCar, on Flickr

start sanding and hammering away to gussy up that tank like new again?

so today the landlords were out when i got home from work. so i quickly grabbed the angle grinder and cut off a few of the tabs i wont be using on the frame. still have to grind the welds off but that can wait. you can see all the green tape as marker to which ones to chop

https://c7.staticflickr.com/9/8060/2...8dd6cc83_c.jpg Untitled by 320iCar, on Flickr

next i grapped the flapper wheel and buzzed off all the residual paint left on the tank, as well as the huge amount of bondo that was still there. so i think for now i might just keep the tank as is. let it get weathered and eventually find a new tank (the same or custom) to properly paint. though that is a long way down the road.

https://c4.staticflickr.com/9/8615/2...bfd56bb1_c.jpg Untitled by 320iCar, on Flickr

then made the measurements for my new front end, and i can't even believe it but it pretty much bolts up. steerer tube is the same dimensions, its crazy. going to have to check the bearing cup profile though. the OEM front uses loose bearings (40 total, all which fell out when i took the front off lol) but the newer gsxr uses an open bearing ring, but you can still pack it with grease. might need to press in new cups, we will see.

ps: '06 gsxr front end with wheel and tire is significantly lighter than '77 kz650 front with no wheel

https://c6.staticflickr.com/9/8606/2...a7a71741_c.jpg Untitled by 320iCar, on Flickr

so i dont have a final vision for the bike, but there are a few things i want to just throw out there for my future memory, and for you guys to comment on or give suggestions.

- the new front end is already modified for proper 7/8" bars such as Renthal or similar. i was going to use clip ons initially but this one already has the clamps. im not a huge fan of dirtbike style renthal bars. someone suggested to me just get them and flip them upside down. i mocked up a mountain bike bar and i did not like it. so i think i might try and find some "clubman" style bars and flip them, similar to whats on my kawasaki. thoughts?

https://c7.staticflickr.com/1/356/19...6d02210f_c.jpg

- i plan on using the MNNTHBX rear turtlehead brake light on the bike. anyone whos into ruckus or groms should know what im talking about. super clean and really bright LED strip light with running, brake and turn signals all intigrated. that being said, im at a cross roads on what to use up front. i have some regular LED turn signals, but that is so.... new? if you know what i mean. i have fallen in love with these bar end turn signals, but then that would mean i can't run bar end mirrors... suggestions?

https://i.ytimg.com/vi/4XFgLWdOfq4/maxresdefault.jpg

http://i.ebayimg.com/00/s/NjIwWDYyMA..._id=880000500F

- im wanting a very very very clean bike. hide as many wires as i can, tuck everything, etc etc. that being said i want this bike to be legal, safe, and rider friendly. so when it comes to controls, im trying to decide what to do. i want to go brand new because why not. i could try and source something OEM like a gsxr, but that is chunky. i could go ebay, but then thats....ebay quality... so i have found a few sites selling "mini switches" like this..

http://www.knucklebusterinc.com/feat...B_FXR11-tm.jpg

my issue with that is that if you let your buddy jump on the bike, your going to have to explain what those buttons are. if someone cuts him off and he needs to use the horn, you dont want him fumbling around trying to figure out what the fuck does what.

then i found these! clean, discreet, and hopefully i can find a matching set for the right with ignition, kill switch etc

http://i.ebayimg.com/images/i/201117...-1/s-l1000.jpg

so im not totally decided on the final vision of the project. i know some features i want and a rough shape. but i want to keep it loose and let the bike design itself to a point

...but then i came across these. continental tkc 80, which they make in a sportbike size of 120/70/17 and 180/55/17. i think i just found what i want this bike to be. an everything tool that i could also go blasting on FSR's with

http://www.ducati.ms/forums/attachme...363.670001.jpg

Spoiler!

I have a POSH Mini-switch on mine. Ordered from WebBike Japan for $60ish including three day shipping from Japan. Come by and play with it if you'd like. Those racing switches are also pretty cool tho. If I had bumped into those I might've gone that direction.

Couple things:

Get an "All Balls" bearing kit for the front-end swap -- They even have a calculator tool for which kit to buy on their site. The #1 Source For Bearings, Seals, Cables & More | All Balls Racing

Renthal Inner Diameter is different than all other handlebars. If you want bar-end accessories this is a no-go. If you want to run both bar-end signals and mirrors off the shelf you'll have to go for an Oberon setup ($$$$$).

Also, holy fuck you're fast.

Quote:

Originally Posted by bananana (Post 8780299)

Also, holy fuck you're fast.

That's what she said :(

front forks installed (obviously not final fitment) and they are literally bolt on. rear swingarm test fitted for measurements. not as much done today but hey, everyone needs a break once and a while.

i really wish i had a garage...

https://c5.staticflickr.com/9/8421/2...4d0f7baf_c.jpg Untitled by 320iCar, on Flickr

https://c3.staticflickr.com/8/7469/2...bbd763be_c.jpg Untitled by 320iCar, on Flickr

https://c2.staticflickr.com/9/8326/2...6935fdc6_c.jpg Untitled by 320iCar, on Flickr

cleaned and painted the rear swingarm, should be ready for reassembly.

https://c1.staticflickr.com/9/8473/2...bd7ddf82_c.jpg Untitled by 320iCar, on Flickr

disassembled and cleaned all the calipers. fronts were already in great shape, im just verifying that they are all clean and working. rears i installed all new parts since they came with the swingarm.

https://c6.staticflickr.com/9/8237/2...d5e63c28_c.jpg Untitled by 320iCar, on Flickr

https://c6.staticflickr.com/9/8486/2...7ef65966_c.jpg Untitled by 320iCar, on Flickr

https://c6.staticflickr.com/9/8329/2...3ac166e5_c.jpg Untitled by 320iCar, on Flickr

https://c7.staticflickr.com/9/8037/2...fc562c08_c.jpg Untitled by 320iCar, on Flickr

Quote:

Originally Posted by E30_vert (Post 8851202)

bump

http://m.quickmeme.com/img/fa/fadc6b...b708b4c5df.jpg

I'm glad this got bumped, it's really cool! I need to get a bike project going...

Quote:

Originally Posted by dustyco (Post 8851228)

I'm glad this got bumped, it's really cool! I need to get a bike project going...

I hope you have money and time because these things will drain both of them.

Bananana is the other one on this forum that I personally know and he hasn't done much of anything to his cafe racer build either in about 2 years or so.

I did the foolish thing and got engaged lol. That kind of puts a halt on the gravy train

Luckily I have no one so that's not going to get in the way :bigthumb: