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Used to have a KZ1100-A2 and my engine never looked as nice as yours when it was new! Did you have the engine covers chromed or have you polished them. Paint looks great! Regret selling mine.

The antique cattle prod-like soldering iron...worked like a dream.

GPz550D1 wrote: Used to have a KZ1100-A2 and my engine never looked as nice as yours when it was new! Did you have the engine covers chromed or have you polished them. Paint looks great! Regret selling mine.

Used to polish every water spot off until I had several covers chromed. The cost was very-reasonable at the time, and the guy did a nice job.
Compliment appreciated.

She was wearing an old mismatched Vetter outfit when I first saw her slouched over in an old driveway south of town. She was pitiful and pathetic, with all that loose-fitting awkward unbalanced weight hanging about...a piece of work, broken fairing support and all.
But something special was hidden underneath all that stuff, and I was fortunate to find it.

Fusing plastic together. Who would have thought...(thanks again SWest)

Black plastic velocity stack sleeves for a stock appearance:

SWEET looking job, cattle prod or not lol. Not sure if you can remove the end of the iron you used but if so then I would find a bolt or screw with threads that match your Iron and heat the end and flatten with a hammer so it is about the size of a dime. It works great for smoothing things out. Being that I am a frugal builder, I have had not problem with the Harbor Freight $17.00 unit and it comes with all the rods you need for different materials. You obviously found something that works so stick with it but think about making the attachment recommended above. Looking fantastic. Great job, keep the pics coming. Be well, jon

Thanks aquaholic

The velocity stack position inside the air box effectively seals the filter media at each opening.

daveo wrote: The new 50mm stacks open just inside, so I can stuff most of the filter material in there too. To install them, the stacks/filters were passed through the openings and attached to the carbs from inside the air box, since there is not enough space on the carb side to fit them.
Utilizing the original crankcase breather hose attachment on the air box, the engine once again vacuums away those intolerable-nauseous fumes!
The reworked air box works much better than I imagined. The engine definitely feels constrained with the intake snorkel-cover installed. Without it, the engine feels like it breathes easier, and the power seems to come on stronger.

Definitely...

Unbelievable, after raising the needles one notch. .................................................. !

I'm pleased with the performance of this revised air box system, and decided to cover up the welded seams with a piece of 1/16" black printable polyethylene sheet.
Just need to bond it on the air box, then route the holes.

Paper pattern taped on the material, and ready for Xacto-cut:


Folding the cut piece:


Trial fit:

This is getting better every day. Nice job. Looks like a factory component!

The bike and I...we like the clean look.




Kawasaki could have made the air box wider in the first place.

Just saw this, Excellent workmanship to give functional improvement