So a sour deal on a yz125 and lack of interest in resale have pushed me into a new project. I am going to build a super moto style bike for the street using a kz550 to power it. I found a wrecked 1982 kz550 in the local craigslist and decided to pick her up. I striped the bent frame of all its parts and that is where i am at now. I have a 96'yz125 that i have striped to the bone in order to get it ready for the kz550 heart transplant. I have weights the yz and kz engines to find that the kz(146lbs) weights 103lbs more than the yz(43lbs). I'm sure i will have a lot of electrical questions since i have to wire the bike from scratch along will quite a few engine questions i'm sure. The only two other bikes i have owned was a 1981 honda twin star and a 96' ninja 600r both of which never gave me any problems so working on bikes is something new (I work on cars a lot). Any way here are a few pics of everything.




^got a set of carbs off ebay along with an igniter, rectifier, starter, starter solenoid

^pulled the vc to check valve clearance and man it was clean in there. (exhaust .004 intake .003) Over winter i will loosen up the clearances since i only plan to put 1K miles on it this season depending on when i get her done.

^from this to....

^....this in a couple hours

I'm hoping to get her mounted in the yz frame this weekend. Any one have a good idea on how to line up the sprockets when i mount her? I plan on using a string tied to each sprocket for a straight reference point.

Comments, critizm, opinions welcome

-Nelson

Progress anyone??? The first cut was the hardest because after that there is no turning back.



A little bit of trimming and the tank and ex-radiator shrouds will fit.....going to keep it looking some what like a dirt bike.

Dude, you are out of your mind! I can't wait to see how this turns out

I got it mounted in the bike but, i need to remove it to do some final welding on the areas i couldn't get to. I also ground down my thumb in the bench grinder accident. So now i have blood, sweat, and i'm sure tears will follow some time during the build. Probably when i get my credit card bill for this past month will all the part purchases i made. I'll get some pics of the bike later today.

This going to be sweet.

Pictures.....

^mocking up the front tubes





^bench grinder accident

^electric tape bandaid ftw!!!!

^this is where i started today

^this is where i finished....i had to remove the engine for final welding

I still have a couple more braces i want to make before i put the engine back in for the last time. Its sucks getting it in and out but, now i need to make new gas tank mounts since the stock one wouldn't allow me to remove the engine....Its getting there

Excellent fabrication, and a most interesting thread.

Was wondering how the down tubes would be added.

Very sanitary work!

Thanks for all the pics!


Ain't got time to bleed!




Good Luck!

this is so cool! as far as exhaust 4-1 would be the way to go, or you could aways build your own header and run a midpipe to a can up by the back fender. wicked! this things gonna be nuts haha

I'm probably going to just go straight pipes since it will be the easiest for me to make. I'm keeping an eye out on ebay for a smashed up header to build off of. I need to pay off my credit card before i buy any more parts though. The next thing i'm buying is a battery so i can build a battery box and start my electrical work.

AWESOME! You da man!

^gutted for some paint

^some of the bracing i added

^trimmed the gas tank to clear the carbs.

So now has come the point where i have a few questions. First is i plan on gutting the stock air box and putting the battery in there along with the rectifier and igniter. I was wondering if the igniter and rectifier need to have air flow over them or if they are inside the battery box (gutted yz airbox) will they be ok? Also, now that i have trimmed the gas tank to clear the carbs i need to figure a way to seal up the huge hole in the bottom of the tank. I went and bought a plastic welder from harbor freight and i dont know if its the welder or just maybe i cant weld plastic but, it didn't work very well. Is there anywhere i can send the tank to get it finished?

I used to ride a friends RM465 and that bike was wicked fast. That looks like it will be a blast to ride.
If your tank is ABS plastic, there is a kit called Hotcha Repair Kit from the Vetter fairing website that might work. The only place to get it supposedly.

craigvetter.com/pages/Online_Store/Online_Store_main.html

thanks for the link. Kinda pricey but, if it comes down to it i'll have to order that kit. If i cant find any place local that can help then i'm going to try to just cut the bottom out of sheet metal and epoxy it together. Not sure if i can find an epoxy that'll hold when in contact with gas.

Hey man, just fiberglass it!, its easy! use a little more resin on the outside of the tank. and sand it smooth. I would slosh a little tank sealer around where you glassed it on the inside so it doesnt get any shards in your carbs,

Thats what i would do.

cheap
easy
and strong!

Well i'm now wiring the bike and have a few questions. Just to make sure i have everything correct before i put power to it i would like a for a few others to check to make sure i have the correct wires going to ground and power.


^Dont ask me why but, i uploaded a pic of my wiring dia. but, this bike is what comes up. Click on it to enlarge it and my wiring dia. will show up :huh:

Ignitor :
D/G - coil ground
B - coil ground
R/Y - 12v source
Y/B - Ground

Rectifier :
R/W - 12v source ( back to the B+ termial since i think this is the charging wire)
B - Ground
Br - 12v source

Correct or not?

I'm also running vulcan coils and am trying to figure out which terminal on the coil gets power and which gets ground. One terminal is green and the other is black....anyone know?

Getting closer and closer to seeing if the engine runs:huh:

nelson8708 wrote:
...trying to figure out which terminal on the coil gets power and which gets ground. One terminal is green and the other is black....anyone know?....

Usually doesn't matter, because the coils don't have polarity. On each coil, attach bat+ to one of the ignition coil primary winding terminals, and attach signal wire from ignition to that same coil's other primary winding terminal.

As far as engine "running," a good fully charged battery should allow running with only the coils attached and powered. Unnecessary to have any of the charging system connected such as alternator, rectifier, regulator, or associated wiring. This is called a "total loss" ignition system, whereby the engine may perform normally until the battery runs down. Racers sometimes use it to reduce weight and gain left turn cornering clearance (by eliminating the alternator and alternator cover).

Besides the ignition wiring and charging system wiring, how much chassis wiring is intended for lights and such?

Good Luck!

Patton wrote:


Usually doesn't matter, because the coils don't have polarity. On each coil, attach bat+ to one of the ignition coil primary winding terminals, and attach signal wire from ignition to that same coil's other primary winding terminal.

Besides the ignition wiring and charging system wiring, how much chassis wiring is intended for lights and such?

Good Luck!

I know on car coils such as an aftermarket msd coil if you switch the two primary wires it will blow the coil (a buddy had this happen). I really dont want to take a chance unless i cant figure out for sure which terminal gets B+ and which gets ground.

I want to have the entire bike wired before i start it. For now i'm not going to put any lights on it but, when i do it wont be much wiring. Just a couple more circuits. Once for the turn signals and the other for head light, tail light, and license plate light. Not that bad at all.

Since all the alternator wires are yellow i take it that it does not matter which yellow wire it goes to on the rectifier box?

Thanks,
-Nelson

I was just wondering. Are you highly proficient at riding a unicycle? If not, I would get so before you try to ride this thing. This monster will be on the back wheel more so than not.

You know-- I just remember, back in the late 70s when Springfield put a XS1100 engine in a flat track bike. The bike was outlawed after the first race because the Harleys had no chance against it. For his victory lap he did two instead; On the back wheel.

This picture might help.

3.bp.blogspot.com/_VDCGGBYmNCk/SXdxbOLhQ...00/kawiscrambler.jpg


...Russ