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TOPIC: Testarossa's 78 KZ1000 Fighter Build

Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #348525

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The red is really close the the original Luminous Red that this bike was.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #348572

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OK, OK, I'll get a new welding helmet! You sold me. I also though that backbone brace was already welded, the fabrication fit is so tight. Again, excellent job on you metal working skills.
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #348898

Auto Dark FTW. I decided to take some welding classes This quarter at OSU. The My prof is sick nasty at welding. He did all of the welding on the Buckeye bullet. I used a standard mask for a week until i bought my own and it is a world of difference. When learning it made one less thing for me to have to worry about. I got a 3M speedGlass it rocks. Welds look good can't wait till spring when i can get working on my bike again.
Columbus, Ohio

Go Bucks

1978 Kz1000 <- first bike and i love it!!
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349048

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porchev914 wrote:
OK, OK, I'll get a new welding helmet! You sold me. I also though that backbone brace was already welded, the fabrication fit is so tight. Again, excellent job on you metal working skills.

Adam you were right, the backbone brace is welded. The tube that I'm talking about is the lower one in between the two downtubes.

Sorry, that I have no new progress pics, but I have been busy on other projects this week. This afternoon, the weather was soo nice here in Houston that I decided to wheel out the black bike and go for a quick ride. Apologies, to those who live in Canada and other regions beset with snow at this time.

Here's a pic of my most beastly Kawasaki



And one of my son with the bike



He got off the bus just as I was pulling in, and made me take him for a ride. Darn, another ride, already, OK twist my arm.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349089

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I see it now, the down tube brace in the front, silly me :blush: And nothing wrong taking a break to go for a ride, especially with your son!
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349097

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February rides are the payoff for the summer in Houston. Can you say steamy?
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349126

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So whats next for your project :woohoo: :woohoo: :woohoo: ?
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349138

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Finish tacking in the last of the frame braces, figure out the chainline and front sprocket offset. Then I need to sort out the footpegs. After that I'll strip it down and finish weld everything. Then I'll start work on the motor, rebuilding my front fork and rear shock. After that it's bodywork and paint. Oh yeah, somewhere in there I'm gonna fab-up a really trick, concealed luggage mount system. I tried a post about that earlier on, but only got one response. I bet I get more after its done.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349175

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Any preliminary plans for the footpegs? I'm interested in your concealed luggage compartment, That sounds very interesting. You'll have my attention at the part where you figure out your chainline and offset needs. I was also wondering if you have checked your front/rear wheel aligment yet? I've read in these forums where it isn't critical that the wheels be perfectly aligned, as some factory bikes have a centerline offset.
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349264

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As for the footpegs, I pinched the GSXR rearsets and passenger peg mounts, but I'm not sure that I care for the look. I'm definantly going to chuck the stockers, so if the gixxer units don't do it, then I'll be off to the wreckers to locate something that will work. I also have tentative plans with the programmer at our shop to make some new rearsets for the zx-10r, so I may adapt a set of those for the KZ.

I just need to talk myself into ordering a new chain and rear sprocket so that I can suss out my chainline. OMR I think that I need that well timed kick in the ass about know.

I haven't checked the wheel alignment yet. I'd bet that the average rider wouldn't notice a centerline offset. Valentio Rossi, Casey Stoner, et al probably would and I'd bet that they may use it as part of the setup on a track that has more lefts or more rights. An offset will affect the lean angle vs. slip angle, but unless it is significant most will not notice the change. At any rate, I will check it and report back with my findings. As you can see, I don't have my brake rotors or any spacers installed at the moment, so my wheels have quite a bit of free play on the axles.

Finally, the luggage rack. At the moment, the plan is quite nebulous, but I would like for it to be a three peice modular system. First will be a typical rear luggage rack that sits above the tail piece. It will mount on the inside of the frame under the plastic tail. This rack will have mounts for pannier style frames on both sides of the rear tire. All mounting will locate off of pins with minimum tools needed for installation/removal. The final and most important consideration will be total concealment of all mounting locations. I wan't to be able to carry enough gear for a week long trip, get where I'm going, drop the bags with one crescent wrench, and ride my super-custom street fighter without anyone knowing about the Clark Kent/Superman act.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349265

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Thats cool Josh, I like now you see it, now you don't luggage system. That sounds like a project in itself! If the wrecker isn't too far away, for a few bucks you could pick up a used chain and sprocket for the time being. Or you could pony up and buy the parts you're going to need anyway. ;)
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349411

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"I just need to talk myself into ordering a new chain and rear sprocket so that I can suss out my chainline. OMR I think that I need that well timed kick in the ass about know."


Size 10 coming at you.... Are you freaking being a dumbass... Chain $90-$130 pending OEM 630 O-ring or ZZZ530, new rear sprocket $30-50... New counter non offset $30, offset $90... <$300 for all new components, only way to go...;)

All in all, for everyhting you've been through in this project, you want to install a USED chain and sprocket???

Here's a hint/tip... LOOK AT YOUR OWN IMAGE, SEE THAT LITTLE GUY WHO'S WEARING THE HELMET WAITING FOR A RIDE WITH HIS DAD... He's counting on you to come home on that bike brother so don't go cheap now, spoend the little extra cash and ride SAFE!!!...

WTF, no way in the used setup for you have no idea of knowing the history of that chain... That sonsabitch breaks on you you are puckied, end of story say good night for you ass is going over the bars and down...

Seriously, go new here...;)

Dave
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349424

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Deep breath, count to ten, OK.

OMR, I think that you are a bit confused. I never said that I would put a used chain on this bike. What I said was that I needed to talk myself into buying the new one. As in going ahead and ordering it, as in prying the $200 that I already have from my grubby, cheap-ass hands. Size 10 accepted, but not for the right reason. I was hoping for maybe a constructive suggestion like "I ordered my chain from X because they have the best price or they are super helpful and allowed me to exchange my counter sprocket when I ordered the wrong offset."

OBTW, lets not break out the safety police badge just yet. If my memory serves, I believe that I saw a video of a certain as yet untested orange KZ900 with one OMR aboard, rocking the safety tee-shirt and safety sunglasses making repeated passes down a residential street. ;) ;) ;) Sorry boss, no harm intended, but I had to get that on in since you asked if I was a dumbass.

1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349435

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The used chain was in regards to others replies...

"What I said was that I needed to talk myself into buying the new one." Ok, if not new then old/used are the only other choices...No...

"OMR I think that I need that well timed kick in the ass about know. "... Sorry if you took offense to it (count to ten) but you brought me into your posting & asked for this...No...

As for riding safely in the clip... You're 100% right and I was being a dumbass for the first intial run, first to admit it... Even at 50mp or less as in that clip, FUBAR could of happened no doubt...

BTW, I ride with a full face helmet, armor protected gloves & Neon Yellow jacket even here in AZ when 115*F... Next will be protected riding pants...

No big deal man...

OMR
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349507

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I suggested the used parts, but only for mock up reasons, not for "in service" parts. I should have been more clear there as it seems to have been misconstrued :blush:
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349564

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porchev914 wrote:
I suggested the used parts, but only for mock up reasons, not for "in service" parts. I should have been more clear there as it seems to have been misconstrued :blush:

I knew what you were saying.

Anyway, I cut off the original upper shock mounts and the grab rail mounts today. I tacked in the mounting tabs for my luggage rack mount. Pictures will follow in my modular luggage system thread.
kzrider.com/index.php?option=com_kunena&...ew&catid=5&id=348190
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349581

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Aight brotha, I gotcher numbers here- Stock complete frame with center and kick stands ;) weighed in on my Nuclear Precision Bathroom Scale (tm) is 53.5 lbs.

I don't mind saying that it felt ALOT heavier than that while holding it centered over my head for equal weight distribution :blink:
bare_frame.JPG
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
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Testarossa's 78 KZ1000 Fighter Build 4 years 8 months ago #349635

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Excellent, I remember when my frame used to look like that.:laugh: Nuclear precision :laugh: I like that.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
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Testarossa's 78 KZ1000 Fighter Build 4 years 7 months ago #350029

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testarossa wrote:
roy-b-boy-b wrote:
As concerning the bearing. I have seen bearings with the same,as you call bumps.
I doubt they are bumps. I would make a wild guess and say the engine has probably set for a extended period in hot and humid weather and condensation set in.

I personally would reuse the bearings. Use scotchbrite to remove the bumps.

Roy

Roy,
Upon further examination, they are definantly bumps. They are in the neighborhood of 0.005" proud. I think you are spot-on with the cause, this bike sat in the Houston, Tx area for at least 10 years. It looks to me that the layers of different material are separating and pushing the top layer up. Just like having rust under your paint. Actually they all appear in areas that show no witness marks from wear. Funny to see just how out of round these bearings are. My concerns about reuse are twofold. Lack of oil pressure, and potential that the bumps cut loose and float around in the oil.

I've seen many like that. Lightly touch them up with some 1000G paper in the parts washer. Go lightly. They'll work fine.
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Testarossa's 78 KZ1000 Fighter Build 4 years 7 months ago #350257

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larrycavan wrote:
[/quote]I've seen many like that. Lightly touch them up with some 1000G paper in the parts washer. Go lightly. They'll work fine.[/quote]

Thats the kind of valuable experience and advice you can get nowhere else but here! I love this board :)

How's the luggage mounts comming along? I'm also curious what headers you find that could be adapted to the KZ. Keep us posted! B)
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end
Last Edit: 4 years 7 months ago by porchev914.
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