Z650 Special...not for the purist.

[Paul Whitehouse]

I've wanted to have a go at building a Cafe Racer / Special, based on a Z650 for a while....with things beginning to come together with the project, at long last, I thought I'd post on here so you can share my pain

Back in October 2017 I hit the `Buy it Now' button and waited to see what would emerge from the back of the delivery van a couple of weeks later. Having built my Z1000 in a similar fashion...from a basket case, I was aware what I was letting myself in for.

With issues needing sorting on both my Z900 and Z1000, that took priority, this pile of bits has been sitting in the back of my garage for quite some time ! Having said that I'd already got a vision on how I wanted it to look and had done a bit of CAD work to see what part of the frame would be attacked with the angle grinder first.

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[Paul Whitehouse]

The obligatory removal of all unwanted lugs and brackets was first on the list and then on to fabricating a couple of seat fixing plates and some threaded bushes, into the frame ends, that will eventually be used to secure my battery under seat tray.

[Paul Whitehouse]

Some of you may remember my post in the `for sale` section of the forum where I sold all the parts off the donor bike that were surplus to requirements. I've since gone on to have a set of wheels built, by Steve at Wheelwise, based around a set of Borani rims. i opted for a slightly wider rear rim than standard so I could run a 130 section tyre...the widest I can run in my recently acquired Dresda swing arm.

[Sgt.Pinback]

I will follow this with big interrest. Borani rims look great!

[Paul Whitehouse]

The engine casings have been vapour blasted and barrels bored to 64mm diameter ready to accept a set of 700 Wiseco pistons. The engine will be built from the ground up and internals replaced if worn or damaged. I'll be looking for a set of slightly breathed on cams....I understand a set of Andrews #20 should do quite nicely...but might be difficult to come by.

[Paul Whitehouse]

it was always my intention to run some period Rickman bodywork. I'll be fabricating a fuel cell to sit under the dummy tank.

[FOZ1A]

Hi Paul, looking good mate! Would you like to borrow a Rickman tank so you can get an accurate replica made?

Foz

[Paul Whitehouse]

Cheers Foz....I might well take you up on that. My original intention was to run a replica tank. I'd contacted TAB Classics to enquire about fabricating one. The price wasn't too bad but obviously I'd need various modifications with regards to the underside configuration so as it'll fit the 650 frame.

I'll see how things go as it's really early days. If it's anything like the drag bike this'll take me years

Hopefully get together and catch up soon mate.

[Swirl]

Nice work, following with interested

[Paul Whitehouse]

A couple of images of my machined and fabricated rearsets.

[Swirl]

Very nice

[ZedHead]

Love the engineering. What CAD package are you using?

[Paul Whitehouse]

Cheers guys....CAD package is SolidWorks.

[Philippe]

Hi Paul
very nice work! Again someone who knows what it takes to modify a bike in a safe way.
GrtZ
Philippe

[Crofty]

I have used GPZ750 Unitrack cams on a couple of 650's with good results. You can keep a decent tick over speed. The Unitrack cams give 1mm more lift than standard. You cam also run Unitrack inlet cam with a Zephyr750 exhaust cam.