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Purchased in Sydney in April 2009, this is a slightly customised 1980- kz650 F1 model originally imported from the USA. It started first go when I unloaded it off the transport truck and clutched it down the street but the starter clutch was faulty when I tried to use the electric starter.
I stripped the engine out of the frame and tipped it upside down to disassemble enough bits to get to the starter clutch, thinking it was like the GPz900R, I assumed the engine cases had to be split to remove the starter clutch but I soon discovered that the secondary shaft comes out once the clutch hub is removed, so I spent a few hours removing the obvious bits till I succeeded in removing the clutch, sure enough it had 3 faulty spring loaded cams hence its inability to start the bike. new kit ordered and should be here in a week.
August 15th 2009
Borrowed a Vacuum guage from my friend Dave and synchronised the carburetors, all appear perfect after the rebuild. Re-fitted the exhaust again only to find there were some rust holes underneath and where the joiner pipe is welded, a small crack. Using some 2mm Satincraft welder rods and around 30A of current (low duty cycle), I was able to flow weld over ther rust holes and re-assembled the exhaust with new copper exhaust seals. Exhaust is now air tight so to speak. Only thing left to do is overhaul the front caliper and bleed the brakes which should then see the bike roadworthy.
July 26th 2009
Lots of work achieved this weekend. Installed the carburettors after stripping and cleaning them, had to reset the fuel float levels a few times to stop the engine flooding. Installed the exhaust system but there is a gasket leak so I will remove them and reinstall with better sealing. Decided to fix the left hand switchgear, the cable was wrapped around the left fork leg, first I needed to remove the dodgy wiring job done by the previous owner and soldered in some better quality bullet connectors. All electrical items now work fine. So with the engine started I took it for a test ride up and down the street. Front brakes might need a service next.
July 12th 2009
Removed rear brake, lubed cam for drum brakes and reinstalled, started work on carburettors.
July 6th 2009
Work on completing engine assembly and have now re-installed engine into frame, fixed ignition leads and cranked engine using electric starter to see how the starter clutch performs. No issues found, engine cranks very well so starter clutch service is 100% successful :)
Need to obtain some fork seals and string front end.
Also discovered that back brake binds a bit, the drum has a steel cam that must need lubricating so I will remove it this week and service it. Plenty of wear left on pads by the look of the foot brake indicator.
June 2009
Starter clutch parts arrived and installed back into engine, no other faults noticed and internals of engine look great.
