1975 KZ 900 , ZRX Swingarm, 89 GSXR front end

Hey all,

First of all my hat is off to those of you keeping the greatest inline four of all time alive.I am truly impressed with all the custom bikes on the forum, you guys are all genious!!


I've been working on this bike since April of 2003.

Then went to Iraq for a bit.

Then an interstate move. Now getting it rolling again. I kind of started this in the welcome section, but Projects is the right place.

I am going to try to post some photo's, Hope to help anyone with questions, and hope to get a few answered myself. I have had the bike all together in the mock up, then started it to make sure everything works. I had to take it all apart again and powdercaot the frame, so now the final build.

I would like to make this bike dependable and well handling, horsepower is really secondary, just want to enjoy the ride.

Feel free to shoot down my work, make suggestions, or share your builds here, information is great, and I have thick skin.

The 2005 photo, is after powdercoating it the first time. We tig welded a Kosman gusset kit in. I had decided against teh zrx swingarm in favor of a GSXR 600 swingarm. The 600 swingarm fits right into the frame no sweat.

Well My buddy has a zrx so we took his swingarm out and the rear wheel, put it under the frame, and man it looked good.

So I had to cut the stock bushing sout, and weld in new frame bushings. This was all done with a series of fixtures a good friend of mine helped to build. He is known only as the "Wizard". Very very good at what he does. We welded in the new bushings in perfect alignment.

Next we were concerned the super stiff swing arm would transfer flex into the rear of the frame. Fabricated more gusstting and welded it all in, soking Powdercoat 1 in the process.

I like to try to make all the little details right, the jury is out on the seat but not for lack of trying.

Removed about an inch from around the bottom of the seat pan trying to get away from that huge seat.

Then took it too a good shop. The guy foamed it up, told me to mark where I would like it trimmed. Seems like a small detail, but I really like the way it turned out.

The frame:

I keep goimg back to the frame cause it makes me so proud. All the welds have been ground to fillets making a smooth looking "sculpture".

This is the view from the front:

The engine has been overbored, all the work was completed when I got the bike from a good friend of mine. The work was done by a reputable shop. All I had to do was clean it up.

Many hours of polishing involved. If you are looking to polish you need this source:

www.tarheelparts.com/

These people are outstanding and very knowledgeable!!

Last month I got powdercoat 2 done after smoothing all the welds to fillets, and having a new steering stop brazed on the neck.

It's a base coat of silver, with a clear over the base. Very nice. Sort of a shiny bare metal look.

Oops I got ahead of myself...

The Mock up!!

Had it all together. Started it a fwe times, then had to take it all apart to do Powdercoat 2.

Now for a trick that may help a few of you.

How many times have you scuffed a new frame paint job trying to muscle the motor in?

Well I had done that enough, the last time I put a new motor into a frame I thought, I bet the japanese put the dam thing in verticle on the assembly floor.

I mounted the motor on a dirt bike stand using the clutch cover threaded holes to secure it to the stand, which held it up verticle, slipping the Frame OVER the engine. It worked very well, and was much easier to avoid scratching the frame all up.

Another view cause it's important!!

Then just have a buddy help you ease the frame over the engine, it's even much easier to get the mounting bolts in, as there is almost no load on the frame.

SO here is the project as it sits in the garage today, engine in feshly powdercoated frame.

I have just received a new wiring harness from Z-1 Enterprises, it goes in next. This is where "my" questions start.

I would like to make the charging system function perfectly. This bike has the old rectifier. The plan is to put a dynotek ignition in. So what is the hot set-up for that? I want to ride this all over the west coast, with no worries.

Welcdome Home! I love your shop. It is nice to have room to walk around your work.

Awsome looking bike! Roy