KZ650 Sleeper Build (KZ1000 engine transplant)

Wookie58 wrote:

I'm with you, I'll take a little time as opposed to spending money whenever possible 

Seems to be the story of my life so far but even more so since I retired, more time than money

Trying to keep costs down where ever possible as you will never get the cash back in the end but that not the point, having fun spending time on it as a hobby. Some guys play golf or have a boat, I have my project bikes.

Some may not understand, but this stuff is fun for us !  

Yeah, my wife knows I am a sick little SOB, could be worse, could be at the strip club gettin drunk

Injected wrote:

could be worse, could be at the strip club gettin drunk

I tried that excuse, was told that ain’t happening either!

Generator cover is a little chewed up so going to give the deeper gouges a once over with a aluminum file. 



This would take forever starting off with paper. 



Not sure when I will get to working on it but will eventually post some result pics.


 

I pulled out my exhaust parts that will make up the system to the mufflers. I need to smooth the outside of the down pipes before using them to mock up. This is a 4 into 2 system with mufflers that look like the original 650 units.



The middle pipe is my crossover tube, just hope there is room for it but won't know till I mock up with the wheels on it.

Started to make a fixture to hold the cam sprockets on my rotary table. I have a 3 jaw chuck for it but need to make a adapter plate which I don't have time for right now. Its faster to make this fixture for the 900/1000 sprockets.



I cut some scrap aluminum for the base plate and will need to make a locating pin to center it. The ends are held on with some T nuts.



Need to make a mount plug with a step to center and locate the sprocket. I will transfer the sprocket mount holes to the base plate then use some clamp shims to clamp it cutting one slot at a time.



When I get the mount plug finished and get to cutting the sprockets I will post some pics.



 

Was able to get out to the garage today and work on this fixture finally getting it finished.



My parting tool would not reach the middle so I cut the last 1/2" by hand with a hack saw, then I faced the end, but the saw marked up outer face which was already to size.



This is the top with the centering pin.



This is the bottom with the pin pressed in.



Fixture mounted on the rotary table, with two M5 bolts holding the plug to the base plate. The small centering pin is nested into the rotary table center.

M6 bolts to mount the sprocket, cut the slot then move the bolt to that slot, then slot a different hole - pretty simple process.

You can also see where I ground a relief so the .425" cam lobe could pass thru. Did that by hand with a Dremel tool. 

I need to pull out a 650 cam sprocket and see what I need to do to bolt it onto this fixture. I know there are only two mount bolts but not sure on spacing or the center hole. Anticipating making another mount plug!

I will leave the slotting to another day, it should only take about 10 minutes per hole once I get it mounted to the mill.

Only got one slot cut after having to figure out the bolt hole separation!



Had to lay it out on a piece of paper using a circle template and a protractor
My CAD is down right now as I just swapped to a new PC tower with better software so the CAD needs to be reinstalled. I jotted down where the end mill slipped in then found out from the layout I needed to go 12 degrees per side from the start hole. It only took about 5 minutes to cut that first slot.

Will continue some other time as I have to cook the meat for Sunday dinner.

Got home early so finished slotting those cam sprockets.





Had a 650 cam sprocket on the shelf so compared it to the 900 sprockets. The center hole and bolt spacing is different.

The material I used to make the 900 fixture mount plug will just work for the 650 sprockets. Will make a 650 plug for the fixture at a later date.


 

Did a few things on this today.

Got the cylinder studs installed and a few covers polished and installed.



Breather cover and oil blocks installed.



Also pulled out some 6061 stock I had forgotten about that will be used for making APE style billet top idler spacer blocks. Bought enough for 4 sets and will mill some up for this engine.



Will post some pics when they are complete.
 

Was able to spend some time making the necessary wiring changes to hook up a 1000 engine to a 650 chassis.

Put male bullets on my Dyna 3 box harness which had been chopped off by PO. 
Made up some signal leads for the Accel coils I will be using.
Fixed the power lead for the Dyna plate spliced off the main harness which was messed up by me back in 1984! (I am using the original harness from my first 650 B2)
Fabricated new wires for the neutral and the oil pressure switches to plug into the harness using the old 90 degree female terminal ends.

The 1000 generator harness had the neutral and oil pressure wires in it and the blue square multi connector that does not jive with anything 650. 

The only wiring item outstanding is to make the stator wiring like the 650 stator with 3 female bullet terminals.