1980 Z650 rebuild
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1980 Z650 rebuild

This is a discussion on 1980 Z650 rebuild within the Project Builds forums, part of the Caferacer.net Forums category; This is my first project bike in over a decade. I started the disassembly last week and there is some good with the bad. Dyna ...

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  1. #1
    Junior Member charles's Avatar
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    1980 Z650 rebuild

    This is my first project bike in over a decade. I started the disassembly last week and there is some good with the bad.

    Dyna ignition, looks fairly new.
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    Dyna coils with bashed frame good and bad. :/
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    This damage to the wire coming from the ignition is odd as it looks man/animal made, there's another section with similar damage but not to bare metal like section. Anyone think a mouse would do this?
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    Hopefully I don't come across too many surprises.


    As she sits now.

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    Last edited by charles; 09-02-2017 at 01:50 AM.

  2. #2
    Junior Member charles's Avatar
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    I spend more time researching and looking for new and second hand parts than I do dismantling the bike and with a small family to look after and entertain getting this bike back to a running condition will take some time. Gotta crack on with it!

    The welding on this bike is very ugly with little tags and blobs all over the place, perhaps the welder had too much sake the night before!

    Check this little spike out, perhaps a strap retaining hook??

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    The carbs came out fairly easily after popping the intake rubbers into the air box. They are not too dirty inside, just the usual 5 year old dried fuel residue dust, they definitely need a clean and new gaskets.


    Do I remove the slides and dismantle the inline carb assembly before ultrasonic cleaning?



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    Sprockets look ok but there is sign of wear on the front, the rear is about the same and the chain has been sitting idle for a long time. It might be best to replace, not 100% sure just yet, they don't look too bad.

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    50% of the electrics are cactus and some components have warts.

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    Looks like the rear tyre got hungry...

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    I must admit that I am very tempted to take the angle grinder to the frame and cut some of the useless tabs off like these that have already been chopped at some point.

    Edit: they are at the rear of the frame over the rear axle. Anyone know what these might have been for?

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    Last edited by charles; 09-30-2017 at 04:44 AM.

  3. #3
    Senior Member hillsy's Avatar
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    The little spike is Mig wire. Possibly from the factory but more than likely from a previous owner.

    Same with the tabs over the axle - they are not stock and more than likely added on as mounts for a luggage rack.

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  5. #4
    Junior Member charles's Avatar
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    Quote Originally Posted by hillsy View Post
    The little spike is Mig wire. Possibly from the factory but more than likely from a previous owner.

    Same with the tabs over the axle - they are not stock and more than likely added on as mounts for a luggage rack.
    Thanks hillsy, with all the little blobs everywhere you may be right and some PO has done some dodgy modifications.


    The belted tab on the coil bracket has me baffled more than anything else as it done not seem necessary to do that to get the dyna coil on, the other coil is fine, and also the front axle is a little short.

    Front brake tomorrow.


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  6. #5
    Senior Member hillsy's Avatar
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    Who knows about the coil mounts - it might have had an ill fitting coil before the Dynas were put on and the mount modified accordingly?

    Whatever the reason, it's not a low mileage barn find.

  7. #6
    Senior Member TrialsRider's Avatar
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    Quote Originally Posted by charles View Post
    ... chain has been sitting idle for a long time. It might be best to replace, not 100% sure just yet, they don't look too bad...
    Buy a new chain and lay it along side the old one, base your replacement decision on the amount of stretch in the old chain.

    About 90% of your carburetor problem is right there in that brass main jet pipe that you already have access to.

    and Mice love to eat motorcycle wires when they get bored. You need a cat to keep them entertained.

  8. #7
    Junior Member charles's Avatar
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    Quote Originally Posted by hillsy View Post
    Who knows about the coil mounts - it might have had an ill fitting coil before the Dynas were put on and the mount modified accordingly?

    Whatever the reason, it's not a low mileage barn find.
    It sure is not a clean barn find, just a dusty old pre-abused shed find, but thankfully it's not too bad.

    Quote Originally Posted by TrialsRider View Post
    Buy a new chain and lay it along side the old one, base your replacement decision on the amount of stretch in the old chain.

    About 90% of your carburetor problem is right there in that brass main jet pipe that you already have access to.

    and Mice love to eat motorcycle wires when they get bored. You need a cat to keep them entertained.
    Damn mice, my labrador is too slow to catch them trying to run on a wooden floor!

    Evidence tells me these carbs have been pulled apart some time in the past and had parts replaced which is a good sign as the float needles looks new, although all the cover screws and jets were almost finger tight.

  9. #8
    Junior Member charles's Avatar
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    Finally ready to take the engine out of the frame and noticed this. Now I don't have OCD but this irks me!

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    I really like the lines of the old Zed's, I'll keep it mostly the same and the colour is growing me.

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    Now my thoughts turn to the engine and what I may or may not need to do there. Compression test next.

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