View Full Version : "EVELYNN" my 81' kz650 build

02-06-2011, 4:38 PM
finally starting a thread as im now consistantly making strides each week on this project. almost a year ago i bought an 81 kz650 in running condition with title for $300 bucks, i did pay for rust too haha! i didnt have time to work on it then as i was still in the middle of my 01 zx6r streetfighter project.

This is definately going to be a budget build. im trying to keep it under $1000 including the cost of the bike and plan to list costs and running total as i go. the only thing that may put me over that limit is welding costs. im turning this bike into a hardtail, but welding is the only thing i am not doing myself since i have almost no skill. im even trying my hand at rebuilding the carbs, ive always been too scared, but figure what do i have to lose!

here she is right after picking her up
hacking all of the subframe off so i dont have to pay my welder as much prep time
finished pulling the electrical harness last week, left one shock attached for easier movement. since this is a budget build and i dont have the money to do a custom hardtail i am planning to have the swinger immobilized instead.
made cardboard templets and transfered to alum. washington has gotten very strict over the last year (ive been pulled over 6 times since sept on my fighter, mostly for lighting and tag visibility) so i am doing two star taillights, in which i will intergrate the turn signals, with the plate mounted horizontally. im going to reuse the bottom shock mounts on the swinger for these
rough sanded left and right
also custom made my front seat pivot for less than a dollar rather than 15-20bucks
bought this seat pan and springs last week, not sure if i will cover it with a marine grade vinyl that will stay looking perfect thru sun and nasty weather or splurge with leather
took this wednsday before loading up to take her to the welder thursday, just love the composition.

my welder is starting on her tomorrow sometime, so hopefully i will go test sit after he tacks and have a fully welded hardtail with seat mounted next week.

breakdown so far including shipping if applicable
Bike - 317
Taillights - 48
Aluminum stock - 5.50
Seat pan n Springs - 42

Total - $412.50

oh, and a tattoo ive been doing work on got added on to friday. still more to go but getting there

02-06-2011, 6:07 PM
Good luck bro!!! Should be a fun one!!!

02-07-2011, 12:15 AM
waiting to see the hard tail i just did my kz last night

02-23-2011, 5:41 PM
well its been a few. my welding project has not been first on the list just because im getting waaayyyy under shop rate. so i have been shopping for parts and working on what few parts i have here until i get the rest back. went to my welders shop last night and we able to make a few decisions before they complete the job
im loving how the new framing is flowing with the bike, if i had more money to spend i would have loved to switch out the tank and be able to squeeze the seat in there all low like. my welder is going to mod the spring bolts on the seat pan so it can sit as close to the wheel as possible on some perches without getting in the way of the fender. we will find out when i start hitting bumps if its ness for me to buy some 4" springs :).
also have gotten the carbs fully disassembled. im not as freaked out now that i have them apart, ive just made sure to take notes and pics and kept all four carb parts separate so its easy to get them back together. I have definately been able to see many things that could definately been a reason why she wasnt running perfect and jetting her will help im sure.

i should be getting the bike back complete from the welder by friday! which would be great since its been snowing everyday and i dont want that frame to get wet while the frame is bare. i have also purchased quite a few parts so heres the break down.

prev total 412.50
carb jet n gaskets 95.99
10leds to insert in
brake lights for turn 5.00
headlight 45.00
exhaust (mine was past
the point of repair)100.00
heat wrap and ties 32.00

running total 690.49

02-24-2011, 12:16 AM
looks good heres mine i did 2 weeks ago just about the same set up

02-24-2011, 2:11 AM
Looks good so far. A smaller tank would look great on there, but I understand budgets. Isn't it ridiculous how much they charge for carb gasket and jet kits?

02-24-2011, 8:34 AM
Isn't it ridiculous how much they charge for carb gasket and jet kits?

Ya! And I'm going to have to buy a few replacement pieces too.

Hey grenade where did ya get that fender? I'm going to try n reuse the front fender on the rear, but not sure if ill be able to make that work or not

02-24-2011, 10:52 PM
my front fender wouldnt fit over the rear tire i tried but mines a 1000 not sure if that makes a differeance , its a trailer fender cant beat 16$

03-11-2011, 10:58 AM
Any progress...pics.........???? Great look on the hardtail bends.

05-28-2011, 8:09 PM
Well its been a while since ive posted... ive been swamped with vehicle projects and housework and just havent had much time to make decent progress on the bike until now.

on a random check of craigslist found a big box of 650 parts for $50. bought it cause i knew it had a new speedo and cable (had been seeing those two for 50 or more so figured anything else in there i could use was a bonus) turns out it had lots of goodies i could use, mostly because my bike has seen lots of outside time. so i got some great controls great wiring harness etc. when im closer to finished with this project ill post a box of stuff with my parts and stuff i didnt need outa this box for $50 and help someone else out!
also got a good set of stock headers w/o the holes and dents and rust mine had for $80
got some led's for $3 and soidered turn signals into my brake lights. ive found thru experience on my fighter that cops over here are turning into deushbags so i decided to run a taillight on each side of the swinger with integrated turns
6" trailer fender, still have half of it left if anyone wants to throw a few bucks my way its yours
not the prettiest from the back
but looks good on the top =) nice weaved vinyl
http://i9.photobucket.com/albums/a67/ninjaracerchick/evelynn/249581_10150199284354178_857804177_6740998_7364847 _n1.jpg
planning on keeping the front fender but choppin it down a bit to fit the look of the rear and get rid of some dents
finally got some extra hands to get this beast out so i can clean her up!
next step is preppin the frame for paint!

im hopin i can get the frame n engine ready and reassembled before i leave for vacation in a lil more than two weeks. should be accomplishable!

05-28-2011, 9:13 PM
Where did you get that weaved vinyl? I think that's perty damn cool.

05-28-2011, 9:24 PM
Where did you get that weaved vinyl? I think that's perty damn cool.

joann fabrics. dont know if theyre only here in wa or nationwide. i thought it was pretty sick also =)

05-31-2011, 2:08 PM
joann fabrics. dont know if theyre only here in wa or nationwide. i thought it was pretty sick also =)

They are everywhere. Where did you get the foam and what kind of foam is it?

06-27-2011, 8:17 PM
well ive made some progress, most of it was done before i went on vacation for two weeks. got all of my frame and random parts prepped and painted. powdercoating was a thought but on a budget build its not really an option, even with a hook up on a good powdercoater it still woulda run me 200. today i spent time getting all the old ball bearing parts out since i decided to switch to a more modern all balls kit. and did some assembly and test fitting, got my fender drilled and mounted (minus some nuts that fit), and tried to get an idea of where im going to put my speedo
mounted up one of my taillights on the bracket to get an idea of the finished look. the left side also is the license plate mount. tomorrow im hoping to get crackin on cleanin up the engine to get it ready to throw back in. im still undecided on if im going to paint the whole block or just remove covers and paint those......

06-28-2011, 7:35 AM
looking great! Keep it up!

07-17-2011, 5:06 PM
progress has been constant, im chuggin away at this point.
got some new rubber, dunlop 404's. the tires on her wernt too worn, but were mismatching and fairly dated so its best to start fresh.
definately needed to do somethin with the wheels, this is what i chose. took a good amount of time but i think it was worth it.
http://i9.photobucket.com/albums/a67/ninjaracerchick/268451_10150255116529178_857804177_7157939_6658295 _n.jpg
as soon as the wheels were dry i got a rolling frame going again!

then i recruited four of my guy friends to come over for a beer and an engine install. definately worth it! made it 100times easier to get it in the frame without fuckin up my fresh not heat cured (till the engine is running) paint, and being able to bolt her in easily.

i decided against painting the whole engine, but opted to paint just the covers also giving me a chance to replace gaskets and make sure things in there looked kosher.
tied into the wheels by doing the valve cover and two side covers with detail and writing black and white. all the other covers and the pedals are all black with the exception of the kickstart which i decided to do white.

now its a waiting game. the gasket set is on the way. while im waiting im going to work on a battery mount and try to start working the wiring harness back on. i also need to figure out what im doing with the exhaust...

the exhaust i purchased is in great condition but the mufflers are gone, my plan was to run some straight pipes anyways. wondering if any of you have at good set up thats mostly stock minus mufflers? am i going to need/want to run baffles? and how should i go about that if i should?

07-19-2011, 12:05 PM
The wheels look great. Did you pull the spokes on the wheel? Where did you get your gasket set from? I am rebuilding and looking for a complete gasket set. Gonna keep watching this one.

07-19-2011, 3:25 PM
The wheels look great. Did you pull the spokes on the wheel? Where did you get your gasket set from? I am rebuilding and looking for a complete gasket set. Gonna keep watching this one.

i painted the spokes on the wheel, they were surface rusted a lil but still solid and straight. i laid the white then the black.... as far as the gaskets i ended up ordering off ebay, so give me a week to receive them and ill letcha know if the quality is there :). you never know!

07-19-2011, 7:23 PM
wow, my fingers hurt just thinking about sanding all those spokes.

07-19-2011, 10:16 PM
Trust me, taping and removing tape was waaaayyyy worse!