HELP ME WITH THIS kAWI 650!

Discussion in 'Old's Cool' started by Hawk Medicine, May 20, 2012.

  1. Hawk Medicine

    Hawk Medicine Coyote's Brother

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    Guys:

    One of my friends just got an unmolested "time capsule" Kawasaki 650 for free and I want to try to help resurect it. The bike was stored in a garage untouched for several years and the engine is now frozen, so we flooded the cylinders with oil and let it sit for a few weeks, hoping that it would loosen up.

    We have the keys, the battery is new and the starter solinoid clicks when you press the starter. There is also a nice aftermarket fairing that came with the bike and includes the headlight and turn signals all of which work and the fairing and tank are near perfect. OTOH, I'm having some trouble getting the clutch to actuate properly. In other words, it won't release. :D The trans shifts perfectly, mileage is almost nill, solid exhaust, good chrome, etc and we don't want to part the bike out yet but the clock is ticking. I know we'll need to replace the intake rubbers, rebuild the brake system, new tires, etc and the owner is up for that but we need to get a running bike. Therefore, we need help.

    Now if this was an Airhead, I'd have had it on the road two weeks ago but I'm totally inexperienced with Japanese bikes and could use some advice and help.

    Is there an online manual for these bikes?
    How does the clutch on these bikes work?
    Whats the firing order?

    I'm of the opinion that what we need to do next is to get the clutch to work, so that we can try to get the rings to free up.

    Thanks in advance.....!


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    #1
  2. JeffS77

    JeffS77 cheap bastard

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    sure that aint a 750 twin ?
    #2
  3. Bloodweiser

    Bloodweiser honestly

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    rope, zip tie, duct tape, whatever the clutch lever and let it sit for a night or two.
    Probably just stuck from sitting, so long as the cable moves freely.

    You could try rolling down a hill and popping the clutch in 3rd or so to free it.
    Freed a 83 yamaha maxim yesterday just like that.
    Fresh battery and wah lah.
    #3
  4. nhmaf

    nhmaf Been here awhile

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    #4
  5. Airhead Wrangler

    Airhead Wrangler Adios Mexico

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    Wait, is this the former "mind sock" talking?
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  6. MightyChosen1

    MightyChosen1 I wanna be sedated

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    I think its a KZ-440 as well. I passed on a running one for $200 a while back because the title was a little "fishy"..


    I would try a little PB Blaster in the cylinders. I have heard folks use it on old frozen tractor motors with good results.
    #6
  7. anonny

    anonny What could go wrong?

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    Tear it apart and find out what is seized.
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  8. Hawk Medicine

    Hawk Medicine Coyote's Brother

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    I looked at the headstock and confirmed that it was a 650 but next time I'm over there I'll take a photo to support that idea.
    #8
  9. Tosh Togo

    Tosh Togo Long timer

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    While you're with a camera, take a snap of the engine displacement tag on the engine: it should be somewhere on the front of the engine, near the case split. Look for an odd small flat area with the engine's size in cc's cast on it. :1drink


    PS- the easy way to break the clutch free is to straddle the bike/engine off/in 2nd or 3rd gear. Pull clutch lever in, then rock the bike back and forth against the frozen clutch until it breaks free.

    -The previously suggested method of "rolling down a hill and popping the clutch in 3rd or so to free it" is unwise, and mildly impossible... with the countershaft moving and the mainshaft/clutch frozen, how do you get from second to third?... and that stuck clutch negates the only other third-gear option which is to put it in third, pull in the clutch, and coast....:rofl

    DAMHIK, but going from neutral into any gear while moving, with the engine off, results in very ugly noises... the countershaft is spinning at a good clip, but the clutch and the mainshaft are stopped. :cry
    #9
  10. Bloodweiser

    Bloodweiser honestly

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    ^may have been unclear.
    The roll and pop is to free the motor,
    Not the clutch.
    #10
  11. Tosh Togo

    Tosh Togo Long timer

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    True, but the OP's clutch stickification needs to be cured first. :norton

    Getting back to the OP... regardless of what size the engine is, you'll have fun. :thumb
    #11
  12. Bloodweiser

    Bloodweiser honestly

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    Agreed.
    I'd try roping it first,
    Unless you're short on time or rope.
    #12
  13. JeffS77

    JeffS77 cheap bastard

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    marvel mystery oil..i have used it to free up a few motors..bump it down in the cylinders and let it sit for a day or two
    #13
  14. kz1

    kz1 Been here awhile

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    Kawasaki did not make a KZ650 twin. The KZ650 was a four cylinder. I think it is also a KZ440LTD.

    +1 on the Marvel mystery oil.
    #14
  15. McJamie

    McJamie STROMINATOR

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    440 LTD for sure.
    We sold them by the truckload in the early eighties. Chain drive would probably make it 81 or 82. 83&84 had belt drive. The 750 twin is much taller, has a disc on the rear, as well as belt drive. They did make a 650 twin, but totally different (Meguro/ W series). And I think 1970 was the last year for them.
    You kind of need to be sure before you start ordering parts. Make sure you take the complete serial number with you to the dealer and let them check for sure.
    #15
  16. kz1

    kz1 Been here awhile

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    Yes, there was the early W1S 650. The Z1 started in 1974 and then in 75 they added the KZ400.
    #16
  17. nhmaf

    nhmaf Been here awhile

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    Yes, the original Kawi 650 twin was a nice version of a 1960s era British twin, and it was a 1960s era bike - this is clearly an early 1980s KZ440, just glancing at the 85 mph speedometers, wheels, electronics, and engine case/head. The link in my previous post takes you to a review section on the Kz440LTD, and you can immediately see this is the same bike.
    #17
  18. Hawk Medicine

    Hawk Medicine Coyote's Brother

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    Well, well...

    Once again, you guys know more about this bike than the owner does and it's definately a 1980 440.:lol3

    NOw the challenge is going to be finding the time to help the owner get if fixed (If possible.) and then do some refurbishing.

    I need another project like I need another hole in my head! :rofl

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    #18
  19. nhmaf

    nhmaf Been here awhile

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    Well, the fortunate/good thing is that there were ALOT of the KZ400/KZ440 bikes made, and parts are much easier to find than they are for the early W650 Kawasaki 650 twin.
    #19
  20. kz1

    kz1 Been here awhile

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    The KZ owner's website is a great place for information, parts, etc...

    www.kzrider.com
    #20