{"id":14610,"date":"2016-01-08T12:02:32","date_gmt":"2016-01-08T17:02:32","guid":{"rendered":"http:\/\/www.chinonthetank.com\/?p=14610"},"modified":"2016-05-05T14:45:04","modified_gmt":"2016-05-05T19:45:04","slug":"kz650-performance-project-1","status":"publish","type":"post","link":"https:\/\/www.chinonthetank.com\/2016\/01\/kz650-performance-project-1\/","title":{"rendered":"KZ650 Performance Project | 1"},"content":{"rendered":"<p>If you&#8217;ve ever taken a look at a KZ650 and researched its history you will know that it was produced to be faster, lighter, and more powerful than any other 650 and\u00a0750 during the mid-to-late 70&#8217;s. \u00a0For that reason I had desired this bike for awhile. \u00a0I spotted one on craigslist for $500 and jumped on it. \u00a0What thrilled me the most over the course of this project\u00a0is what had been\u00a0discovered inside\u00a0the engine.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Craiglist.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"size-full wp-image-14613 aligncenter\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Craiglist.jpg\" alt=\"KZ650_Craiglist\" width=\"611\" height=\"436\" \/><\/a><\/div>\n<p>It was found in a\u00a0shed sitting for\u00a0over 15 years. \u00a0Naturally some things would be wrong with it. \u00a0It had dry rotted tires, a frozen master cylinder, oil leaking out of the engine halves, ugly decals, and a hideous sissy bar. \u00a0First things first, lets make sure it runs.<\/p>\n<div style=\"text-align: center\">\n<p><iframe loading=\"lazy\" width=\"500\" height=\"375\" src=\"https:\/\/www.youtube.com\/embed\/dTtPUFE4Z7w?feature=oembed\" frameborder=\"0\" allowfullscreen><\/iframe><\/p>\n<\/div>\n<p>GOOD LORD! \u00a0That&#8217;s certainly not the sound of a stock engine. \u00a0Later on I had discovered this KZ has been highly modified with\u00a065mm pistons (+3mm over\u00a0stock), Andrews #20 Cams (.350 lift vs .304 stock cams), and a Martek 440\u00a0electronic ignition system. \u00a0All of which screamed to the tune of a Kerker 4-1 exhaust. \u00a0It was now time to tear down the engine, frame, and rebuild her with some additional performance upgrades along with\u00a0a new look.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/cylinders_before.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14625\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/cylinders_before.jpg\" alt=\"cylinders_before\" width=\"958\" height=\"718\" \/><\/a><\/div>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_head_before.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14624\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_head_before.jpg\" alt=\"KZ650_head_before\" width=\"958\" height=\"718\" \/><\/a><\/div>\n<p>Opps I managed to chip the\u00a0piston wall during removal of the circlip\u00a0. \u00a0This is going to suck.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_cracked_piston.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14623\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_cracked_piston.jpg\" alt=\"KZ650_cracked_piston\" width=\"780\" height=\"585\" \/><\/a><\/div>\n<p>It&#8217;s just my luck that Wiseco no longer makes the 65mm kit. \u00a0Instead I had to take a small step backwards if I was going to stick with the Andrews Cams. \u00a0So I purchased Wiseco&#8217;s 64mm kit and a used stock cylinder block on eBay. \u00a0Cylinders were bored out by <a title=\"PowerSeal USA\" href=\"http:\/\/www.powersealusa.com\/\" target=\"_blank\">PowerSeal USA<\/a>\u00a0and fitted to the new pistons. \u00a0Since this is Part 1 of this\u00a0project I am still working on\u00a0reassembling the engine. \u00a0At this point I continued with the tear\u00a0down of the motor.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_case_halves.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14642\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_case_halves.jpg\" alt=\"KZ650_case_halves\" width=\"780\" height=\"585\" \/><\/a><\/div>\n<p>Lucky me, more upgrades! \u00a0Those are\u00a0performance springs installed on the clutch. \u00a0I couldn&#8217;t be happier.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/clutch-springs.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14640\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/clutch-springs.jpg\" alt=\"clutch springs\" width=\"825\" height=\"619\" \/><\/a><\/div>\n<p>With the engine torn down I began the restoration process. \u00a0First with vapor blasting the engine.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_vapor-blasted.png\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14639\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_vapor-blasted.png\" alt=\"KZ650_vapor blasted\" width=\"1079\" height=\"608\" \/><\/a><\/div>\n<p>Following that I had the frame and miscellaneous parts\u00a0powder-coated. \u00a0This was my second time using <a title=\"Prestige Powder Finishing\" href=\"http:\/\/www.prestigepowder.com\/\" target=\"_blank\">Prestige Powder Finishing<\/a>\u00a0in Newark, Delaware. \u00a0They primarily work on\u00a0industrial contract jobs but they will do frames on the side. \u00a0Here is the before shot.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_before_powder.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14638\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_before_powder.jpg\" alt=\"KZ650_before_powder\" width=\"619\" height=\"619\" srcset=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_before_powder.jpg 619w, https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_before_powder-400x400.jpg 400w\" sizes=\"(max-width: 619px) 100vw, 619px\" \/><\/a><\/div>\n<p>And here is the after shot. \u00a0The\u00a0finish is\u00a0&#8216;Satin Black&#8217;.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_after_powder.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-medium wp-image-14637\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_after_powder-1100x1100.jpg\" alt=\"KZ650_after_powder\" width=\"1100\" height=\"1100\" srcset=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_after_powder-1100x1100.jpg 1100w, https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_after_powder-400x400.jpg 400w\" sizes=\"(max-width: 1100px) 100vw, 1100px\" \/><\/a><\/div>\n<p>The head was rebuilt by <a href=\"http:\/\/www.marautomotive.net\/\" target=\"_blank\">MAR\u00a0Automotive<\/a>. \u00a0Thanks to Ed for the recommendation.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ_rebuilt_head1.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14632\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ_rebuilt_head1.jpg\" alt=\"KZ_rebuilt_head1\" width=\"768\" height=\"1024\" \/><\/a><\/div>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ_rebuilt_head2.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14631\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ_rebuilt_head2.jpg\" alt=\"KZ_rebuilt_head2\" width=\"1024\" height=\"768\" \/><\/a><\/div>\n<p>The dirty carbs kept bugging me\u00a0so I gave them a good wash using an Ultrasonic Cleaner and Simple Green. \u00a0Clean on the left, dirty on the right.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_sonic_carb_clean.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14634\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_sonic_carb_clean.jpg\" alt=\"KZ650_sonic_carb_clean\" width=\"1024\" height=\"769\" \/><\/a><\/div>\n<p>Keeping in mind that air-cooled bikes are not particularly\u00a0fond of hot summers and stop and go city streets I\u00a0thought it would be proper to add an oil-cooler to the KZ650, especially with all this extra heat\u00a0I&#8217;ll be packing. \u00a0Oddly enough there is a simple solution. \u00a0A direct oil sump swap from a 84 GPZ750. \u00a0You&#8217;ll notice the exchange for the oil cooler at the top. \u00a0KZ650 on the left, GPZ750 on the right.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Oil_Sump_Swap.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14636\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Oil_Sump_Swap.jpg\" alt=\"KZ650_Oil_Sump_Swap\" width=\"859\" height=\"644\" \/><\/a><\/div>\n<p>Time to get back to the frame and wheels. \u00a0Black spokes, polished hubs, and Avon Roadrider for tires.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_painted_tires.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14630\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_painted_tires.jpg\" alt=\"KZ650_painted_tires\" width=\"768\" height=\"1024\" \/><\/a><\/div>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_front_end.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14629\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_front_end.jpg\" alt=\"KZ650_front_end\" width=\"768\" height=\"1024\" \/><\/a><\/div>\n<p>I replaced the fork seals and added performance springs with\u00a015w fork oil for better dampening. \u00a0I also added a Tarozzi fork brace for better handling.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Tarozzi.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14626\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Tarozzi.jpg\" alt=\"KZ650_Tarozzi\" width=\"1024\" height=\"1024\" srcset=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Tarozzi.jpg 1024w, https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Tarozzi-400x400.jpg 400w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/a><\/div>\n<p>I continued with handling upgrades by installing\u00a0<a href=\"http:\/\/www.progressivesuspension.com\/\" target=\"_blank\">Progressive Suspension<\/a> on the rear.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_rear-sprocket.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14627\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_rear-sprocket.jpg\" alt=\"KZ650_rear sprocket\" width=\"1024\" height=\"1024\" srcset=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_rear-sprocket.jpg 1024w, https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_rear-sprocket-400x400.jpg 400w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/a><\/div>\n<p>The KZ650 stock sprocket sizes are\u00a016T on the front, and 42T on the rear. \u00a0I&#8217;ll be running 17T, 42T. \u00a0This will drop the RPM&#8217;s 1,000-1,500 while cruising on the highway. \u00a0I&#8217;ve heard the stock setup revs high at 70mph and this should help with that. \u00a0At this point I am glad\u00a0the KZ is finally\u00a0standing on its\u00a0own again.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_standing.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14628\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_standing.jpg\" alt=\"KZ650_standing\" width=\"1024\" height=\"1024\" srcset=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_standing.jpg 1024w, https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_standing-400x400.jpg 400w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/a><\/div>\n<p>I am using a KZ900\/1000 front fender. \u00a0It looks better and wraps around the tire to prevent slinging rain and rocks. \u00a0Aesthetically you&#8217;ll notice I blacked out some pieces and added black euro style handlebars. \u00a0I also added LED turn signals.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ_LEDs.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-full wp-image-14643\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ_LEDs.jpg\" alt=\"KZ_LEDs\" width=\"1024\" height=\"768\" \/><\/a><\/div>\n<p>I found a\u00a0rough design for a Fender Eliminator on\u00a0a KZ650 forum. \u00a0I purchased an aftermarket LED taillight and began drafting up a template.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/FullSizeRender-2.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-medium wp-image-14667\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/FullSizeRender-2-825x1100.jpg\" alt=\"FullSizeRender (2)\" width=\"825\" height=\"1100\" \/><\/a><\/div>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/IMG_2398-e1452129899590.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-medium wp-image-14666\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/IMG_2398-e1452129899590-825x1100.jpg\" alt=\"IMG_2398\" width=\"825\" height=\"1100\" \/><\/a><\/div>\n<p>I then tried it on for size. \u00a0Once I get the fitment right I&#8217;ll then go ahead and fabricate the final version.<\/p>\n<div class=\"cott-article__copy-img\"><a href=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Fender-Eliminator-Test.jpg\"><img decoding=\"async\" loading=\"lazy\" class=\"alignnone size-medium wp-image-14668\" src=\"https:\/\/www.chinonthetank.com\/wp-content\/uploads\/2016\/01\/KZ650_Fender-Eliminator-Test-825x1100.jpg\" alt=\"KZ650_Fender Eliminator Test\" width=\"825\" height=\"1100\" \/><\/a><\/div>\n<p>Currently this is all I have to share at this time. \u00a0I am in the midst of polishing my engine covers. \u00a0I hate polishing at times but love how it looks in the end. \u00a0Philadelphia&#8217;s own <a href=\"http:\/\/www.bikeexif.com\/xs-650\" target=\"_blank\">Bill Becker<\/a> has agreed to assist me with\u00a0my engine assembly and after that I should only require a fresh paint job.<\/p>\n<p>Hope you enjoyed reading this. \u00a0Stay tuned for Part 2.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>If you&#8217;ve ever taken a look at a KZ650 and researched its history you will know that it was produced to be faster, lighter, and more powerful than any other 650 and\u00a0750 during the mid-to-late 70&#8217;s. \u00a0For that reason I had desired this bike for awhile. \u00a0I spotted one on craigslist for $500 and jumped [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":14632,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":[],"categories":[223,65],"tags":[],"_links":{"self":[{"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/posts\/14610"}],"collection":[{"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/comments?post=14610"}],"version-history":[{"count":58,"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/posts\/14610\/revisions"}],"predecessor-version":[{"id":14699,"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/posts\/14610\/revisions\/14699"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/media\/14632"}],"wp:attachment":[{"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/media?parent=14610"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/categories?post=14610"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.chinonthetank.com\/wp-json\/wp\/v2\/tags?post=14610"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}