TOPIC:

My experiance told me that if the crank and rotor are scored bad, they will never lock together.the rotor is softer, so it will likely be the worst.the big problem is that it can screw your whole summer. if u need to replace the crank, u need to pull the motor and split the cases.
i would be tracking down a spare crank now, if u feel the crank is scored.

i ran into this problem along time ago i tried to use a rotor from a 900 on a 1000 crank it spun after about a week i then looked a little closer and found they don't have quite the same taper. i went diggiong thru all my stuff and found the right rotor that actually came off the crank in the first place problem solved. the difference in tapers wasn't much but it was enough.

I'm surprised that no-one has spotted my non-standard fuel tank yet. It's from a KZ750, and I made it fit by welding in a piece of 3/8" bar across the underside of the top frame tube. I had to cut off the original mounts on either side of the frame. Also had to take off a sheetmetal boss near the back of the tank. Pictures to follow.

testarossa wrote:

DIY fork spring compressor.

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Now is see what u mean by the 750 tank. when i saw it before, i thought it was an LTD tank.
How does the new spring compressor work? will this replace the spanner socket hook wrench, some how?

Mark,
The 750 tank was too cheap to pass up on ebay for $50. I like the extra capacity, and that thing is clean inside. Zero rust. I didn't realize at the time that I would have to make so many mods to make it fit. However, I have discovered that I like fabricating, so no worries.

On to the spring compressor. Your correct, it replaces the hook idea and will actually work on more modern forks. That metal sleeve is usually made of plastic on the newer bikes and that hook would do damage. Anyway, two bars that stick out of the hex are hollow and have pieces of 3/8 round CRS that slide in/out. Basically you slip the hex over the top of the fork and slide the bars into the two holes in the sleeve (where I had the hook before.) Press down with your hands and slide the keeper tool(not pictured) under the bottom jamb nut on the dampner rod. Then you have an easy time disassembling the two jamb nuts. I'll do a similar pictorial to the teardown when I put the new seals in my newer fork.

One thing to keep in mind for everyone whose running an upside down fork. Get a FSM for that bike and read up on the service interval for your fork oil. Usually, you'll have to change oil every couple of riding seasons, and you need to get the springs out to properly fill the oil. So you need the fork tools even if you never have a seal leak.

That is gonna be one Bitchin' lookin ride when its done!

Martynbiker wrote:

That is gonna be one Bitchin' lookin ride when its done!

Thank you sir! I sure hope that your right. I'm shooting for subtle with excellent craftsmanship. Personally not into the super shiny, 100% chrome, bling bling bikes. I can appreciate these, but not my style.

What is the fuel capasity of the kz750 tank? it actualy looks smaller than a kz1000 tank in the pic. thats why i thought it was an LTD tank.
The kz1000 is 17 liters and the LTD is 13 or 13.5l, i beleive.the z1900's were something like 15 l.

if u haven’t already, u should put the output shaft in the cases, and mount the cases. this will give u a chance to see how the 2 sprockets are lining up. u may have to do some clearancing on the frame for the chain. the chain may rub on the inner part of the lower footpeg mount. also depending on the offset u run, u may need side clearance. with a 1/2" offset, u will clear the frame, but 5/8" will require some work.
Your swingarm may even have an offest that is not noticeable. Its worth checking.

Mark,
Good points on checking the clearance. I'm very close to doing this. What size chain are you running? I was thinking of using a 530. I need to get a chain and sproket set. As far as the fuel capacity i'm not sure on the exact size but it definantly has more volume.

i currently have a 5/8" offset 630.
it has worn out, so i am switching to a 530.
the 530 gians u a wee bit more clearance, even though they are suposed to be the same width as a 630.
if u need to go 5/8" i can help guide u through the snag points.

Thought that I should post some progress pics. I started working on the frame braces today.



Here you can see the top tube braces and the tank mount that I added.







Here's one the lower braces in progress. I plan on adding a cap piece, and putting in a cross hole with a one inch tube like the Sanctuary frame.

A few more pics of today's progress.



Here's that lower brace again. Top cap and through hole tacked in as promised.



More top tube braces like the Sanctuary frame.



Starting to look like something.



I really like these pictures that are somewhat backlit. It minimizes the fact that every panel is a different color.

Excellent progress! I'm jealous that you're soooo much further along than I am, but you are making great headway and the quality of your workmanship looks good. I have two questions for you though. (1) What is the "sanctuary frame" you are refering to? (2) What is the width of the rear wheel your using and do you have any idea how much CS sprocket offset you are going to need? I guess thats 3 questions, but I will be facing the same problems you're tackling so I'm anxious to see your resolutions
Adam

Adam,
Thanks for the compliments. As for your questions:1)pm me with your email addy and I'll drop some serious frame brace info on you. Mark1122 was kind enough to forward all of this to me and I'll do the same for you. The Sanctuary frame is from Japanese company who builds KZ racebikes. The text is all Japanese but the pictures will show you all you need to know. 2)My rear wheel is stock '95 GSXR 750. 5.5" wide for 180/55/zr17. 3) I'm not real sure exactly what offset I'll need but I'm told it should be either 1/2" or 5/8" You'll know when I do, what the final number is.

Fantastic!!
Your work looks as nice as Santuary. Well done.

Awesome man, thanks. I look foward to gleaning juicy frame bracing info for the KZ. There should be a drooling emoticon, shouldn't there?

hOW ABOUT THIS.

Got a couple of new gussets fitted on the neck today. Also, got a new toy.





This tube needs to be shortened so that it will slide up some. BTW it isn't welded yet.



Check out my new welding hood that I scored today.



Tractor supply had it on sale for $79.99. Auto darkening, adjustable shade from 9-13, solar powered, and cool flames. If you haven't got an auto darkening hood, get one. It already improved my welds. No guessing where you are at when you strike the arc, and no adjustment time after you can finally see. Remember that the average person takes a whole second to react, and alot of stuff can go wrong in that second.

Nice helmet. looks like a good paint theme for the bike. Pretty WILD.