cdiver666
Active Member
Hi, about a month ago I bought my first motorcycle, a kz650. Since I wanted a bike to work on, (and didn't have much cash) I was looking for an older bike, and quickly heard about the cafe racer thing. I decided to go in that direction because I like the minimalistic looks and the focus on performance.
A pic when I got it:
I didn't waste any time tearing it apart but first I wanted to make sure I could get it running. The guy told me he would do so before he dropped it off, but he didn't. Oh well. I hooked up jumper cables from my car, and had my brother hold them to the battery cables on the bike (it didn't come with a battery) while I vigorously kick started it. After more than a few tries, it did start and idle. However my brother went inside since it was too loud; I don't remember if I hit the kill switch or if it died when the jumper cables came off. I was just scared the positive lead was going to hit the frame! Anyway I haven't been able to get it to start since.
I originally (and still do) wanted clip on bars. However, the cheapest ones I could find were like 60 + shipping (partsnmore), and the cheapest clubmans were 25 with like 5 shipping (motorcycle superstore was cheaper than ebay). I got those on as a "test fit" and took off the seat, fender, inner fender, and etc. I think I may down the road cut the bars on the ends a couple of inches on each side. The main concern is master cylinder clearance. I was going to flip the headlight ears upside down and try that out but the led signals didn't come with washers and the bolts are too short. So they won't just bolt on. I will deal with those later.
I originally wanted to use the stock foam and pan and shave off the second hump to make it look like a solo seat. However the frame was in the way, and the sewing machine broke while trying to make the cover for it. So I said, screw it, I'll shoot for a real cafe seat.
Using part of the stock pan and some sheet metal I started to make a seat. It bolts right to the frame where the battery box used to. I am trying to make the rear hump out of sheet metal. Like a regular curvy type. It is difficult. I can't much continue on that front however since I ran out of welding rods. I do plan on bondoing it smooth.
On a side note: I recieved a craftsman arc welder for Christmas and have been using that, however it burns through the metal extremely quickly and is very difficult to get it to arc. I had no trouble on the arc welder in school, but this one is hard. Maybe I'll switch to a cheap mig? Opinons please.
Here is the start. I have more pieces that just bolt on so I can mock it up quickly, but without the rods I can't do much.
I also bought led turn signals on ebay (19 with free shipping) and a 50 volt 10,000 uF capacitor. I have not been able to get the bike to start with the capacitor, but considering how difficult it was to start before, I don't think thats much of an issue.
Here's where I cut the frame. This piece will be angled up about 30 degrees to allow tire clearance. The regulator, capacitor, and kill switch will be relocated under the seat. The power will run right from the capacitor to the coils with the kill switch in between. I will be removing the electric starter, and re-wire the whole bike. Oh, how hot does the regulator get when the bike is running? If I were to stick my hand under the seat to hit the kill switch and I accidentally touched the regulator would I get burned? I could make like a guard if thats the case.
I think I want to take off the front fender as well, for looks. However, having never ridden a motorcycle, does anyone think the fender protects you, the rider, from kicking up rocks and such? I do plan on having a full face helmet. Spring is a ways away up here so I don't have any riding gear yet, but I will.
Last night I got the carbs off (what a pain in the ass) and am going to clean those up. The bike didn't come with air filters, so I plan to get the emgo pods from z1.
Here it is torn down. I don't want to get into the engine until later down the road. I want to have it ready for spring. But down the road (once I can afford it) I would like to do an 810 big bore, with stock heads and jugs. (with 750 sleeves).
Here are the carbs, I have never cleaned carbs out before but I'll see what I can do. Any suggestions? Please let me know. I won't be cleaning them in the house by the way. I was just looking at them.
The bike came with just about all stock parts, and I won't be using a lot of them. If you need a part (like battery box, side cover, stock turn signal) let me know I'll let it go cheap or trade for something aftermarket.
A concern at this point is the coils were not both the same. One looked stock and bolted to both holes, and one was larger and was only bolted to one (since the other didn't line up). Would I be okay to go with dyna coils at 3 ohms and then likely upgrade to dyna s electronic ignition later?
Well if you managed to read all of that (or just looked at the pictures) please tell me any comments or suggestions. This is my first motorcycle, and first motorcycle build. Thanks
A pic when I got it:
I didn't waste any time tearing it apart but first I wanted to make sure I could get it running. The guy told me he would do so before he dropped it off, but he didn't. Oh well. I hooked up jumper cables from my car, and had my brother hold them to the battery cables on the bike (it didn't come with a battery) while I vigorously kick started it. After more than a few tries, it did start and idle. However my brother went inside since it was too loud; I don't remember if I hit the kill switch or if it died when the jumper cables came off. I was just scared the positive lead was going to hit the frame! Anyway I haven't been able to get it to start since.
I originally (and still do) wanted clip on bars. However, the cheapest ones I could find were like 60 + shipping (partsnmore), and the cheapest clubmans were 25 with like 5 shipping (motorcycle superstore was cheaper than ebay). I got those on as a "test fit" and took off the seat, fender, inner fender, and etc. I think I may down the road cut the bars on the ends a couple of inches on each side. The main concern is master cylinder clearance. I was going to flip the headlight ears upside down and try that out but the led signals didn't come with washers and the bolts are too short. So they won't just bolt on. I will deal with those later.
I originally wanted to use the stock foam and pan and shave off the second hump to make it look like a solo seat. However the frame was in the way, and the sewing machine broke while trying to make the cover for it. So I said, screw it, I'll shoot for a real cafe seat.
Using part of the stock pan and some sheet metal I started to make a seat. It bolts right to the frame where the battery box used to. I am trying to make the rear hump out of sheet metal. Like a regular curvy type. It is difficult. I can't much continue on that front however since I ran out of welding rods. I do plan on bondoing it smooth.
On a side note: I recieved a craftsman arc welder for Christmas and have been using that, however it burns through the metal extremely quickly and is very difficult to get it to arc. I had no trouble on the arc welder in school, but this one is hard. Maybe I'll switch to a cheap mig? Opinons please.
Here is the start. I have more pieces that just bolt on so I can mock it up quickly, but without the rods I can't do much.
I also bought led turn signals on ebay (19 with free shipping) and a 50 volt 10,000 uF capacitor. I have not been able to get the bike to start with the capacitor, but considering how difficult it was to start before, I don't think thats much of an issue.
Here's where I cut the frame. This piece will be angled up about 30 degrees to allow tire clearance. The regulator, capacitor, and kill switch will be relocated under the seat. The power will run right from the capacitor to the coils with the kill switch in between. I will be removing the electric starter, and re-wire the whole bike. Oh, how hot does the regulator get when the bike is running? If I were to stick my hand under the seat to hit the kill switch and I accidentally touched the regulator would I get burned? I could make like a guard if thats the case.
I think I want to take off the front fender as well, for looks. However, having never ridden a motorcycle, does anyone think the fender protects you, the rider, from kicking up rocks and such? I do plan on having a full face helmet. Spring is a ways away up here so I don't have any riding gear yet, but I will.
Last night I got the carbs off (what a pain in the ass) and am going to clean those up. The bike didn't come with air filters, so I plan to get the emgo pods from z1.
Here it is torn down. I don't want to get into the engine until later down the road. I want to have it ready for spring. But down the road (once I can afford it) I would like to do an 810 big bore, with stock heads and jugs. (with 750 sleeves).
Here are the carbs, I have never cleaned carbs out before but I'll see what I can do. Any suggestions? Please let me know. I won't be cleaning them in the house by the way. I was just looking at them.
The bike came with just about all stock parts, and I won't be using a lot of them. If you need a part (like battery box, side cover, stock turn signal) let me know I'll let it go cheap or trade for something aftermarket.
A concern at this point is the coils were not both the same. One looked stock and bolted to both holes, and one was larger and was only bolted to one (since the other didn't line up). Would I be okay to go with dyna coils at 3 ohms and then likely upgrade to dyna s electronic ignition later?
Well if you managed to read all of that (or just looked at the pictures) please tell me any comments or suggestions. This is my first motorcycle, and first motorcycle build. Thanks