1977 KZ650 B1 Cafe Racer

[jeffw]

Well I decided to build my own wiring harness from scratch ordered 16 ga. thinwall auto wiring through this site http://www.vehicle-wiring-products.eu/VWP-onlinestore/cable/thinwall.php and the connectors through this site www.vintageconnections.com. I figured that I didn't want splice onto the existing wiring and this way it would have upgraded wiring and connections and cut everything to the correct length and create a cleaner wiring harness.

 

[jeffw]

More progress engine in frame

After getting everything mocked up and sitting down I realized the stock location for the pegs are not going work, too uncomfortable. I plan to use the stock location for passenger pegs fliping the gear shifter (now will be gp style). The rear brake lever I plan to flip and rotate the brake rod so it still works properly. I then plan to cut the brake lever and straighten it and then weld on a 90 degree peg. Will post pictures as I progress on it and document for a cheap way to move the rear sets instead of paying the $300+ for the ones offered for my bike.

 

[jeffw]

More progress on the bike, replaced all the bearings. I got the brackets fabricated, just have wiring and misc. parts to go.
Front bracket that will attach to triple tree and house the gauge & ignition

Rear bracket that will fill in the space below hump & act as a plate to attach my rear tail light to (will house battery and maybe a few other electronic bits)

I got this seat pad ordered http://www.roccitycafe.com/store/cbfbpad/0118121818.jpg should be pretty comfortable and look way better than my first attempt at a seat pad. I plan to get the tank polished up to the next level a few minor scratches that I want to get rid of and have somebody powdercoat clear 8). I will get some photos posted up this weekend with the brackets shown and a rollling chassis.

 

[jeffw]

More progress pics

Decided to try this product for bare metal tank http://www.amazon.com/Sharkhide-Metal-Aluminum-Protectant-Quart/dp/B002W8MXTO instead of the powdercoat clear due to the possibility of yellowing over time plus this is going cost about 1/3 to do

 

[DesmoBro]

looks good so far

 

[rocketman]

lookin good! nice gauge!

 

[jeffw]

Just finishing up the last bits of the electrical, I can see the light at the end of the tunnel just a few minor jobs to go. Went ahead and ordered new clutch plates & springs. I had a guy on dotheton design me a gauge face for digital gauge (danmoto). I think it turned out pretty good and should add a nice finishing touch to the gauge and tie it in with the bike and get rid of some of silly symbols that it had before

 

[diggerdanh]

Love the gauge face, and of course the K at the bottom! I'm thinking of one of those Danmoto gauges. How was it hooking everything up?

 

[jeffw]

Pretty straight forward, haven't fired it up yet to see if everything works but seemed to be a straight forward following wiring diagrams and the one it came with. Definately eliminated some of the wiring that the original system had which is nice.

 

[CafeRacer650]

Hey Jeff, thanks again for the info you shared with me. Also realized I hadn't signed on to your build thread. I like what you've done with it so far! Will be watching.

 

[jeffw]

After much head scratching deciding what I am going to do for rear sets. I have decided on these http://oldschoolspeed.com/products/#prettyPhoto (diy kit with solid pegs). I am going to run them out of the passenger foot peg location, at 6'-5" it's actually about right for ride position from testing out sitting on the bike with the clipons. This way I have no problem with the kickstarter as the ones offered by Raask interfere and cost three times as much.

 

[rocketman]

Passenger spot seemed to be the most logical here too! 6'1" i sat on the bike several times to test. Let me know how you make out with the rear brake, keeping spring tension on the pedal.

 

[jeffw]

Well I thinking of running linkage from the rear set to (e) pedal and creating some type of small lever to hook it to, If that doesn't work, I will see if I can create something that goes directly to the rear drum.

 

[jeffw]

Final Mock-up before paint polish and cleanup

Front Brakes mounted w/ new s/s lines & double banjo from apex brakes

 

[NBraun]

Nice work so far. Did the Kz have the lower splitter for the original brake lines? Is that dual banjo with the master cylinder?

 

[jeffw]

Ya it did but I ended up ditching it for dual banjo at the master cylinder since my m/c has a built in brake sensor

 

[NBraun]

Is it an aftermarket M/C? If so what kind? Id like to do the SS lines on my suzuki and it seem's it probably be cheaper/easier to do what you did here.

 

[jeffw]

http://www.ebay.com/itm/280977691728?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 this is the item I got, there was a guy over on kz650.info that used on his bike and worked pretty well. It has both the clutch lockout switch for the starter and the brake light sensor on the m/c

 

[NBraun]

Thanks dude! those are looking pretty good! Ill have to keep up on the build to see how they work out for ya! ;D

 

[jeffw]

More progress pics
About the only time the wife will allow the tank inside

New seat pad should be pretty comfortable