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TOPIC: 650 SR 1981 (z750L engine)

650 SR 1981 (z750L engine) 21 Oct 2017 04:24 #773373

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I bought a Kawa 1981 650SR with a z750L engine last year. The plan was to bought hobby in the winter building and renovate and in the summer season driving :) So I will try to be some lay back (not stressing) and not doing everything at the same time.. but have something to-do next winter also :).

Last winter I rebuild the carbs, adjusted valves, new coils, removed rust in the gas tank, new mirrors, new master brake cylinder.
Everything I did was to be able to drive the bike through summer season, missing was success. and I have driven around 900 miles.

I have discovered leak from the top (properly the o-rings in the oil channel) and the engine is using oil. The plan for the winter is to take out the engine, check the cylinders and if needed honing them, replace piston rings and investigate the top to se what need to be done, replace the oil seals in the valve at least, but must see if more is needed.

In parallel to these will I look for a nice seat, cafe racer style, I don`t want to cut in the frame... but we will see...
The original plan was to paint the frame part by part where it`s needed, but today have I started thinking about strip down everything and do a proper paint of the whole frame...

If you know about company who make good quality cafe racer seat who will fit my frame without any cutting and modification of the frame, will I be rally happy for your advise.

I need also to look at the brake and suspension during the winter.

But I will start with the engine....

Attached some photo of my bike, from the summer season.








bike last year, last winter is was doing a rebuild of the carb, adjusted the valve
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

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www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 21 Oct 2017 04:30 #773374

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Yesterday and today have I worked with getting the engine out of the frame. I have never done something like these before so I took it slow and was taking a lot of photos for future use. I have also order a lot of parts from the Partzilla for rebuild of the engine.

Before I started to take out the engine was I warming up the engine and tapped of the oil and removed the oil filter.

The plan further now is soda blasting the engine before I open it up.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 21 Oct 2017 04:34 #773375

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Is it somebody know about company who make on request or have available cafe racer seat for my frame, so I don`t need to cutting in it?
It must be quality seats, so I don't fall in part after a short while...

I have added some photos of my existing seat and frame shape.

I have found one page, it looks to be identical frame as mine, on of the last pictures is a 650 SR?
www.motorcycleseatsdirect.com/1979-1980-...ete-motorcycle-seat/
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 21 Oct 2017 06:07 #773380

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I fitted a cafe seat to my bike without cutting the frame. The company that made my seat is no longer around, but it can just be a matter of finding a few seats the style you want that have thorough measurements, and measuring your frame from every angle to make sure it will fit. It looks like your SR has the same advantage my LTD did in that the frame is shorter than the standard version.

Then just find a way to mount it. Mine is rubber mounted to a simple aluminum support I riveted together and bolted to the stock seat hinges and catch, but there are endless ways to do it. Here are some places that have seats to get you started:

www.dimecitycycles.com/motorcycle-parts.html?cat=2206
gftpstore.com/Seats_c6.htm
www.airtech-streamlining.com/vintage/vintageseats.htm
www.legendary-motorcycles.com/caferacerseats.html
www.tuffside.com/default.asp

Of course, it could be the seat you found bolts right up, in which case, ignore me altogether. :)
1980 KZ750 LTD
Edmonton, Alberta
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650 SR 1981 (z750L engine) 12 Nov 2017 09:51 #774501

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The last weeks have I worked with stripping the gas tank and the seat.

The seat base (original) is now primed and painted with 2k paint, tomorrow will I send it to Denmark to a person I have found (have done a lot of nice work with seats). So the next days must i figure out what design and color I want :)

The gas tank has been stripped, primed and painted (underside), I will now store the tank to later in the winter, planing to deliver it to pro paint shop for painting the top side of it.

All the parts for the engine has arrived last week from Partzilla.

Plan further is to soda blast the engine on the Saturday is the plan, and then open up the engine from the top side.

I will properly working the frame during the week, strip everything of.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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650 SR 1981 (z750L engine) 24 Nov 2017 14:56 #775030

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A mail stone for me now, next will I send the frame and swing arm for blasting and painting together with the gas tank.
In the meanwhile will I look the overhaul the forks and strip down the engine for paint.

The seat will be rebuild next week also.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 25 Nov 2017 08:54 #775050

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Today have I soda blasted the engine, and I`m happy with the results. Will do some manual sanding also before paint.
Before the paint shall the engine be open up and checked.

Attached some photos of to days work.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 06 Dec 2017 22:38 #775680

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The seat builder is not finish with the seat, please see attached picture. He has built in on the original seat "base". TO make the look flat, has I less foam on the rear side of the seat, but I`m not planing to have people behind me :)
As you can see I`m not go in for 100% cafe racer, I want a bike I can use for longer trips also... so I will have dirt covers etc also....

I open up the engine some days ago also, and got some surprises on the condition... maybe the cylinders need to be bored and something has to be done with the valve...
kzrider.com/forum/2-engine/607482-cylind...all-condition#775657

The painter is finish with the frame and the swing arm, and are now working on the tank.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 09 Dec 2017 13:56 #775773

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I got my gas tank from the painter on Friday, I`m really happy with the results :)
See attached picture.

Start of next week will I clean the block and the top and deliver it to a workshop for overhaul.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 10 Dec 2017 10:53 #775798

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Frame received, looking forward to start mounting parts :)
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 17 Dec 2017 13:30 #776217

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I have now delivered the block and top a engine shop, and the plan is to bore up the cylinder block and install overborre pistons, so the new engine will have 810cc, valves will also be overhauled.

Looking forward to start up the engine with new pistons and cylinder walls / top in good condition.

It has started to coming in parts also... so on the start of the new year is the plan to start mounting the bike back again on the frame.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 17 Dec 2017 13:44 #776219

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You are doing a really nice job Gordon. I'll keep watching and reading, Stay with it!
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
06 ZG1000 Concours
02 Trans Am ... not enough time
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650 SR 1981 (z750L engine) 17 Dec 2017 15:19 #776224

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Lots of shiny bits to put all back together.
Looking forward to your reassembly.
B)
Rob.
CANADA
http://www.kz650.info/

'78 KZ650 C2, 125K kms, Rickman fairing, Delkevic ex, EI, K&N, ATK fork brace, steering damper, braced swingarm, Progessive & Koni, 18" Z1R front wheel.

'00 ZRX1100, Ohlin's shocks, fork brace, steering damper, ELS +4, Corbin seat, Gimbel bugspoiler.
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650 SR 1981 (z750L engine) 17 Dec 2017 22:57 #776284

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The plan is to overhaul all the mechanical part of the bike and take the electrical next winter, so will re use the electrical for these season.
Cross my fingers to be finish to the summer :)
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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650 SR 1981 (z750L engine) 18 Dec 2017 22:49 #776327

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Removing the base gasket was a interpretative test, but it helped with some good music :)
So now is the surface clean... next step when I got part is to flush the engine with diesel to remove all dirt inside the engine....
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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650 SR 1981 (z750L engine) 19 Dec 2017 09:53 #776341

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The cleaning gasket surfaces makes me batcrap crazy. Glad to hear you are through that and back to reassembly. I did not remove the pistons when I did mine. Keep us posted.
79 KZ650 SR
80 KZ1000 Z1 Classic
83 KZ1100 LTD
06 ZG1000 Concours
02 Trans Am ... not enough time

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650 SR 1981 (z750L engine) 09 Jan 2018 09:45 #777102

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I have now sandblasted the brake caliper + div parts, and started to paint them, when I`m finish with the paint.
Will I start to rebuild the front forks, remove the oil pan for flushing the engine of dirt and then rebuild the engine (will properly have the top and the block back in next week).

I have attached some photos.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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650 SR 1981 (z750L engine) 15 Jan 2018 22:54 #777321

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I received the top from the engine shop some weeks ago, honed the valve and the valve seat. Yesterday I reassembly the valves.
I have attached some photos.
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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650 SR 1981 (z750L engine) 20 Jan 2018 10:23 #777491

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The last days have I rebuilt my front and rear wheel. New bearings, tires etc...
Please see attached photos.

It was pain in the ass... to get the bearings out when you don`t have done it before and don`t have perfect tool for it... but I found a technique for and 3-4 broken scew drivers :) hehe

Tomorrow is the plan to rebuild the front suspension and paint some parts.

Will pickup my new bored and honed barrel next week, so I can start to assembly the engine soon also.

It going forward, plan is to drive in the summer :) I will not repaint the wheel and rebuild the electrical system these time,
must have something to-do next winter also.

Have a nice weekend further!
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine

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650 SR 1981 (z750L engine) 22 Jan 2018 00:03 #777553

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Yesterday I assembly the front suspension, please see attached photos. Looking forward to test them :)
they needed some overhaul :)
1981 KZ650-D4, with 1981 z750L engine (Wiensco 810 big bore).

Project:
www.kzrider.com/forum/11-projects/607213...sr-1981-z750l-engine
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