the 810cc Conversion (AKA Mad Kaw)

[madmac74]

 Ok , so I've been Threatening to rebuild my '78 KZ 650 C2 for awhile now.  Well the time has come.  The shop is finally done, complete with heat and Insulation. So begins the task of treating Mad Kaw diasease!!

I've been gathering parts for well over 5 years now and I think ( after my last delivery) that I have everthing I need.  The only thing I'll be farming out will be the Boring and Machining. Sounds straight forward so far , Lets see how I do.  

I've taken a bunch of pics, hopefully in order of teardown, remember I'm a Mechanic not a Cameraman !! LOL  I'll try and post 'em up as I go.


Hope you like....

MAC  
http://s240.photobucket.com/albums/ff137/forkliftech74/The%20810%20Conversion%202010/?albumview=slideshow

[ironpan65]

Great Pics...
Looking forward to seeing how the rest of the build goes....

[madmac74]

  Ok I found the source for my inspiration in this thread..


http://articles.kz650.info/documents/1977FebruaryBigBike-BonnevilleKZ650.pdf

[madmac74]

Bump
 

[Kaw-meister]

definitely liked the big bike article

[madmac74]

I found my 2 nd gear problem , according to Kawasaki.  It was popping out of gear...Check out the black burnt bits on the  2/3 shift fork ..... . I'm told this indicates contact with the gear, which inturn
popps me outa 2nd gear.

[madmac74]

 Here's a good comparison of the exhaust ports on the head.  Right is stock, Left is by Jeff  
More to come... with pics!!

[ironpan65]

Mac....there is an extra 650 engine here if need for Trans Parts or Whatever....


Was that a common issue for those bikes -  second gear?

[madmac74]

 not to0 shure Pan....But I think having 50000KM's on it prolly just wore the fork out.  Thanks for the offer by the way. You should check out http://forums.kz650.info/index.php for a set of side covers. great bunch of guys there !!

MAC

[madmac74]

Mac....there is an extra 650 engine here if need for Trans Parts or Whatever....


Was that a common issue for those bikes -  second gear?

I may take ya up on that ,Pan,  looks like my order got dropped by Bikebandit   not available 

[madmac74]

 Thanks to PAN, I have a parts engine , that's in pretty decent shape. I pillaged all that I can use from it, for now, and will begin re-assembly this week!! Here's a couple shots of Jeffs excellent work in the mean time, and mine too (lol). We actually did quite a bit of work to the head . Jeff took all the points down in the combustion chambers, the valve guides, and re worked the exhaust runners nicely. He also put a knife edge on the valve tops to get more flow. I did a lot of work to the cooling areas in between the combustion chambers. There was actually a factory flaw which limited the amount of airflow over #2 . I did the same on the cylinders too. Excellent ol' tricks I had forgotten about!  I did My part by double lapping the valves in also , and putting on new valve seals. This thing should be a screamer when its all done !!

[madmac74]

cleanin up the case halves

[madmac74]

[madmac74]

 and here's the top half...

[madmac74]

 Its all together on the bench, except the top end , I'll get a pick and post it up soon . Ain't this vintage stuff fun ? 
MAC