The Free Kawasaki Z650 Project

Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
My mate collected the Z650 wheels from Triple S along with the disc adaptor rings which have been cerokoted, not used that finish before. Had the wheels done in a satin gold powder coat.
 

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Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
Fitted the tail section and new seat, so I can work out how to mount the ER6 rear lamp. Realised the bike doesn't have a seat lock.. pity as new ones are £82..

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Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
Another hour on the bike today, few parts arrived in the post, so could fit the tank, and the front forks. Waiting for new rear wheel bearings, then can get new tyres fitted, and soon it'll be on its wheels again.

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jlgace

Active Member
I like your subtle but effective selection of mods here while sticking it out with the original look/wheels. I was going to say I liked the wheels raw until I saw that gold satin. Never expected to like it, but have to say I do. Doesn't hurt that it appears the coater did a fantastic job, think the green and gold combo is going to be smashing. As others have noted, it looks like you do excellent work.
 

Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
The powder coaters specialise in bike parts, they know what areas need to be masked off etc. t would've been easer and cheaper to fit modern forks / wheels but wanted to keep the OE look.
 

Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
New Renthal bars fitted, Tommaselli throttle and R6 master cylinder, the engine mounting brackets have been painted and fitted with stainless bolts. Its become clear that only one of the engine bolts is OE, the rest are a mess. Have ordered a metre of 10mm stainless bar to make new replacements.

Got a problem fitting the side stand, the new Kawasaki retaining bolt doesn't fit, its 10mm while the kickstand takes 12mm. Not sure if the 12mm is original or its been fitted to a modified stand / frame in the past.

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doc_rot

Oh the usual... I bowl, I drive around...
DTT SUPPORTER
DTT BOTM WINNER
Kickstand bolt is a shoulder bolt.
 

Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
Got the correct rear wheel bearings and soon fitted them without a problem, so should've gone to local tyre place, got tyres fitted and straight back on the bike to make it a roller at last. But that will have to wait another 8 days as I'm not allowed to drive for 28 days after a sudden illness. I'm doing ok, could've been a lot lot worse. In the meantime, fitted the headlamp mounting bracket, but the headlight itself is in pretty bad condition, so ordered a new one.

A couple of spacers have been replicated in stainless.. one a rear wheel spacer and the other a engine mount spacer. The originals being in poor shape. Finally cleaned up the rear brake plate, still needs a bit more time, but had enough of polishing for now.

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Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
Couple more new parts arrived.. new headlight shell and front mudguard, its a replica by PMC in Japan. Also finally fitted the rear light, bit fiddly, and still need to cut the lower section down as its not needed, then paint the whole bracket black.

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Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
Few more jobs completed today, the HEL brake lines arrived, and fitted no problem. Painted the side panel badges, which took ages, had to use a tiny brush and a magnifying glass. On fitting the side panels to the bike, realised that one of them had a mount broken off. Looked for a replacement on Ebay, and they all seem to have the exact same broken tang.

On the positive side, tomorrow I can drive again, so will be straight round to the local tyre place with the wheels, and fingers crossed have the bike on its wheels soon... assuming they have the correct sizes in stock, but if not its only a 24 hour wait.

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pidjones

Over 1,000 Posts
Most all motorcycle covers are ABS plastic that bonds strongly using ABS plumbing cement and general purpose plumbing cleaner. Plastic to make new tangs is usually given freely by repair shops doing wreck repairs. Cut out what you need and glue it on. If needed, fiberglass cloth can reinforce, impregnated with ABS cement.

If ABS cement is not available locally (or Amazon), there are recipes online - primarily ABS shavings dissolved in acetone.
 

Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
Most all motorcycle covers are ABS plastic that bonds strongly using ABS plumbing cement and general purpose plumbing cleaner. Plastic to make new tangs is usually given freely by repair shops doing wreck repairs. Cut out what you need and glue it on. If needed, fiberglass cloth can reinforce, impregnated with ABS cement.

If ABS cement is not available locally (or Amazon), there are recipes online - primarily ABS shavings dissolved in acetone.
Just checked Amazon, and it is available, so ordered a bottle, next need to make the missing tang somehow.
 

Bevelheadmhr

Coast to Coast
DTT BOTM WINNER
After a few delays, finally got new tyres on the wheels so at last the bike is a roller again. It was surprising hard work on your own, those old wheels are very heavy.

I found a weird problem with the bike that I've never seen before.. the RHS upper shock mount is 16mm in diameter, while the LHS is 14mm... I'll make a suitable spacer to make up the difference, but it is very odd.

I know the bike had been crashed at some point in the past, so maybe one top mount was damaged and another was used as a replacement.. the frame had been crudely painted before I got it, so couldn't tell if that area had been welded.

Cant fit the side stand as the bolt it uses is non standard, so have to make one, in the meantime its going to have to lean against the wall in the garage.

Not sure what engine the bike is going to have, probably either the original 650 motor, but rebuilt, or perhaps a GPz750 engine, which also needs rebuilding.. or maybe just fit 750 pistons to the Z650 engine. Be a while before any of that happens, so this Z650 will have to stay leaning on the garage wall for some time yet. But that's ok, got other bikes to work on this summer.

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