KZ650 Sleeper Build (KZ1000 engine transplant)

I finished machining this drop shim for the RH muffler, got it installed and sealed the muffler to collector pipe joint with 3Bond sealant.

 

I also got the cam cover back on after marking the center idler bracket, its more than I thought at a .160" so its staying on the bike as is because the cam timing is set perfect. The cam end plugs are now sealed and hopefully there are no leaks to come.

 

Not sure if I want to mess with this down the road, but I do know I don't want to try a longer cam chain just to fix this small annoyance.

If anything I would just try a thinner billet shim under the current bracket and see if it will do the job. Timing the cams again is no big deal compared to swapping a cam chain just to make it easier to take the cam cover off. 

Tomorrow I plan to put the coils on and start it when its cooler in the morning. I want to see if those leaner pilot jets were the right choice.

 

Just spit-balling here but wouldn't it be relatively simple to brace the sides of the idler then remove the required amount from the top (space permitting)

I bolted the idler to piece of aluminum then cut the top off and lowered it to the same height as the sprocket then welded it together. Doing it like this doesn't change cam timing or amount of chain adjustment.  

I was thinking lowering the engine by removing the long bolts and using a small floor jack 1/2" might be the easiest way to remove the cover. Lots of room in there when they are out. 

Vinsky wrote:

I bolted the idler to piece of aluminum then cut the top off and lowered it to the same height as the sprocket then welded it together. Doing it like this doesn't change cam timing or amount of chain adjustment.  I posted a photo of the mod here but don't see it now.

Indeed, this was just an alternative way to achieve the same outcome but may give more clearance given the frame/engine combo here. 

I have no opinion on the idler, but I can say that I've been reading every post recently, waiting for a test ride report!  This bike is just SO COOL!  Hope you get it running to your liking, Injected!  

I started the engine this morning and right away it sounded much crisper, but the plugs are still rich. When I stopped to put the ColorTune plug on it I had a hard time getting it started again even though it was warm. I had the old battery on there when I did my compression test and it may have been a bit weak.

I am hoping its just a air screw setting, so once I swap out the battery to get it started again I should know where I am at as far as pilot jetting. There would be no harm in taking it for a test ride as is, just black spark plugs.

It did this same hot start thing the last time I had it running, no issue with starting from stone cold.

I still need to fix the petcock orientation and handle length before I can take it for a test ride.

wrote:

Just spit-balling here but wouldn't it be relatively simple to brace the sides of the idler then remove the required amount from the top (space permitting)

 

I came up with the same conclusion the other night...

 

Just need to check the cam cover internal dimensions to make sure it clears. This design keeps everything the way it is except clears for the interference at the top, plus no dowels or loose pieces to worry about.

No dropping the engine to take the cam cover off, there is only 1/16" of clearance from the engine case to the bottom frame rails on this conversion.