!PROJECT! KZ650 Cafe racer

[zeiss150]

I wish it was "normal" smoke but its totally a London fog

I pulled the engine apart so there will be no video, I left the jugs on thought because I know its not the cylinders.

If its the carbs I'll go crazy... I've taken this engine apart 4 times now because of the smoke and if its not even the engine

The smoke is a white smoke and it doesn't smell like fuel. I was under the impression that to much fuel gives you black or gray smoke. I did rejet the carbs when I got the bike the main and the pilot jets got reduced. The P.O. had them way to big for the bike (as evidenced by the soot covered compression chambers)

Also the plugs don't get soot covered they get black and look wet.

I'm so close to looking for a KZ750 replacement engine and just starting over.


I pulled the head and I started to check the valve stem seals... I checked exhaust valve cylinder 4 and the back side of the valve was totally dry

Then I pulled intake valve cylinder 1 the back side of the valve was covered in oil... but the valve stem seal looks fine... its new... I put it on myself.


I'M SO CONFUSED!!!!!!!! HELLLLLLLLLLLLLLLLLLLLP!

Maybe I should just by a new used engine and start over... I hate to give up but I want to ride my motorcycle.

Matt-

[Brewtus]

Make sure the valves are relatively tight in the guide, also. Put it back together with fresh valve guide seals. Have a beer. Relax. This is supposed to be fun, remember?

[Mike900]

Did you use a torque wrench & did you install the two O rings between the cylinders & head?

[zeiss150]

Yes I used a torque wrench and Yes I used the two o-rings between the jugs and the head... They were not new though. As long as they're not torn or compressed they should work just fine. I can't believe that old o rings would cause that much smoke. Dumber things have happened though.

I have no problem spending the $1.50 on new o-rings (I just didn't thing they were bad)... I don't want to put it back together and have it still smoking just to find out its not the o-rings.

Matt-

[Mike900]

Well I'd certainly try new O rings & check the head & cylinders for warping. It sounds like you used new valve seals & there's just not many places for oil to get into the combustion chamber. On some engines the rings are marked & that mark has to be up when put on the pistons.

[anakinkenobe]

Its funny you mention the Kz750 swap i had a guy come into work and after talking alittle bit he has a ton of '79kz750 parts and a motor so i am thinking to do that swap after i get my stuff straight on my bike...

[zeiss150]

Thank God its done! I took it out today. I love it! It runs awesome. I'll post up some pictures and Video later this week.

Here are some pictures of me riding it today...




Its so fun to ride!





I like this shot... I think it looks bada$$!




Thank's for all the help I've gotten and nice comments over the months that I've had this post up. I will post up some professional pictures in the next week along with a video. If you have any questions just let me know.

Thanks again, Matt-

[Torques]

Well, did you find out what caused the smoking, did you replace anything since the last post? The bike looks wonderful.

[zeiss150]

Yes I did. I replaced the pistons, rings and jugs. So I took the top end down again and bought some pistons with rings on ebay. I already had a set of stock jugs. I put it all back together and with a few minor timing problems out of the way.... vrrrrrrrrroooooooooommmmmmm. NO SMOKE! Oh by the way, never underestimate how important the point gap is. seriously Makes a huge difference. I started a new thread to get the problems worked out after I put it back together because I this one is so long I didn't thing anyone would read it.

Thanks Matt-

[rstnick]

Have fun with her Matt.
Looks great!

[V2K_CCTX]

The KZ650 and KZ1000 always remind me of "Mad Max"

[anakinkenobe]

Very Very nice, i like it alot.... Im elbows deep in an engine rebuild lol...

[V2K_CCTX]

are you the Toe Cutter ??!!

[zeiss150]

are you the Toe Cutter ??!!

Nope. I still have all my toes. I busted up a few of my nuckels on this build but that's it.

Matt-

[V2K_CCTX]

Lol

[zeiss150]

my bike seems to have a nice idle at 1200 rpm. now, I think my tac is "off". Is this a common problem. My timing light doesn't give me rpms so I'm not sure what the real idle rate is. any suggestions?

I'm guessing that a normal idle is about 800 rpm's.

Thanks, Matt-


PS. I'm working on a video. stay tuned Kawi fans

[V2K_CCTX]

Originally Posted by zeiss150

Nope. I still have all my toes. I busted up a few of my nuckels on this build but that is.

Matt-

want to find an old Z1 like goose rode in Mad Max

[87handmedown]

I haven't said much up to this point, but I've been following your build from the beginning. All I have to say is I'm so envious of what you've done. I really wish I had the time to do something like this. The motorcycle looks AMAZING! Have any videos of it running?

[zeiss150]

I'm working on the video now. I'm trying to put something cool together so it may take me a few days. I'm also pretty sick right now (stupid flu) so that's gonna slow me down.

I would encourage anyone to do this sort of a build. It doesn't take much money (if you do all the work yourself). If you spend a few hours a week it may take you a few years but that's how long it took me. I started working on this project in the summer of 2007. For me this is my hobby. So if it takes me 6 months or 6 years its the challenge I enjoy, the time is unimportant. I have a 1972 Datsun 240z that I've been working on for 7 years. I should be done with that by next summer. Then I'll start on my next motorcycle project. I've already got it worked out in my mind... its gonna be beechin.

Stay tuned, Matt

[zeiss150]

I was having problems with the plugs fowling. So I did some searching and I discovered the "wired George coil relay mod". I checked all the problems I was having and according to wg I would bennifit from this mod, so... I did it. And it worked great! It fires up on the first kick now and It idles smooth and has good power. The plugs are golden brown now and not powder black. before the mod I was only getting 10 volts to the coils. After the mod I was getting over 12. That loss of 2 volts makes a big difference.

The only thing left to do now is get the timing dialed in and then It should be golden.

I'm still working on my video. If I can get it done tonight I'll post it up.

Stay tuned!

Matt-

P.S. Here's the link to the coil mod...

wiredgeorge motorcycle carburetors - Vintage Japanese Motorcycle Carburetor Sales, Rebuilding and Restoration - Repowering Ignition Coils To Get Full POWER!