Testarossa's 78 KZ1000 Fighter Build

Ok so I bought this 1978 KZ1000 A2 basketcase for $400. It had been yard art for probably 10 years, but was mostly complete. The engine had compression on the kick starter, so I figure that it could be made to run for not too much money. This not being any sort of special model, and not nearly complete enough to do an original resto I have decided to do a streetfighter. So far I have purchased a 1995 GSXR 750 that will donate a 43mm USD front end with fairly modern brakes, and a monoshock swingarm. Best of all, it will allow me to run the 120/70r17 and 180/55r17 that I want. Other good things about this particular Gixxer are that it has a cable driven speedo just like a KZ, and the swingarm pivot is narrow enough to fit the KZ frame with some spacers.




This is the quick and dirty mock-up.

Unfortunatly I can't find a pic of the KZ assembled when I brought it home b/c I recently had a little computer crisis and suffered a lot of data loss.

I plan on documenting this build so that others can use this thread as a assembly manual if they choose to use the same parts. I am a machinist by trade, and I plan on doing as much of the work myself as I can.



Here's a pic of the GSXR Steering stem. I pressed it out at work the other day. It presses out through the bottom of the lower triple clamp. Unfortunatly it's a bit short and the bearings are different sized to the KZ bits. I will machine a hybrid stem that fits the GSXR forks and the KZ frame using standard KZ size bearings. Once I know for sure that this works I'll post a copy of the print. That way you can take it to your friendly local machine shop to have one made. Or pay me to do it;)

Thanks for sharing...we are all watching

Now on to the heart of the beast. I started tearing into the head today. I must say that I'm mostly pleased. My plan is to run a mostly stock motor at first, and later I want to build a very streetable Hi-Po motor. I'm thinking KZ900 crank with some 10.25/1 Pistons to bring it up to a 1075. I already scored a set of BS 34's uber cheap. I must say that the "mega torque" thread is right up my alley here.

Anyhoo, for now if the stock pieces can be reused, they will. So I am pleased to report that my cams measure good, all the valves look good, and all shims and buckets were rotating freely with no funny marks. On the bad side, I discovered that the tach drive gear is quite bent, I launched one of my valve spring keepers into low-earth orbit, and I found something wierd on my cam bearings.




What's up with those bumps on the bearing? All of the lowers look good, but most of the uppers look similar to this. BTW, the cam bearing journals are smooth. Any clues on what caused this?

Mcdroid wrote:

Thanks for sharing...we are all watching

I'm hoping that you guys will give me the appropriate, well timed kick in the ass to keep moving forward. I may have to sell plasma to get this thing done, but somehow I will.

Looking forward to seeing it finished!

"kick in the ass"... Oh hell, that's no problem here.... :blink: :huh: :dry: :laugh:

For the steering stem, fab up a coupler that presses into the lower tree and use the KZ stem... That's pretty much how the rest of us have done it but then again, not a machinist. :blush: I'd think you'd have no problem lathing that Suzuki stem for your needs....

As you have stated, image/record/document your methods and you'll make a whole slew of new friends here...

Now, more pictures damn it! :woohoo:

OMR

testarossa wrote:

Now on to the heart of the beast. I started tearing into the head today. I must say that I'm mostly pleased. My plan is to run a mostly stock motor at first, and later I want to build a very streetable Hi-Po motor. I'm thinking KZ900 crank with some 10.25/1 Pistons to bring it up to a 1075. I already scored a set of BS 34's uber cheap. I must say that the "mega torque" thread is right up my alley here.

Anyhoo, for now if the stock pieces can be reused, they will. So I am pleased to report that my cams measure good, all the valves look good, and all shims and buckets were rotating freely with no funny marks. On the bad side, I discovered that the tach drive gear is quite bent, I launched one of my valve spring keepers into low-earth orbit, and I found something wierd on my cam bearings.motor sitting long time oopsies! if its just on top side of bearing id guess its from oil drying up from motor sitting for a long time

What's up with those bumps on the bearing? All of the lowers look good, but most of the uppers look similar to this. BTW, the cam bearing journals are smooth. Any clues on what caused this?

Uh Plum.... Think you forgot to add something here such as a remark to what the bumps are or a question, either way old man, you forgot to complete.... :huh: :dry: :blink: :laugh:

OMR I had considered your idea about the steering stem, but I was concerned about the KZ stem being welded into the lower clamp. So did you grind out the weld, and then press out the stem? Which direction did the stem press out? This sleeve would def. be easier to turn than a whole new stem. A little less "Government Work" would be easier to get approved by the Boss-man.

Plummen, I must know what your comment was about my bearing pic. I have two guesses 1.)No comment-if you can't say anything nice... 2.)Hit quote button, then pass out as the unconscious finger left clicks the Submit button. I'm really dissapointed about those bearings, b/c other than those bumps, I'd reuse them. And those little buggers are kinda expensive.

Anyways, I didn't make too much progress today. Just popped off the jugs, and I'm pleased with the state of the union of the cylinder department. I also gave my work bench a nice protective coating of 10w40. I was forced to go for a ride on the zx-10r today since the weather was soo nice in Houston today.

Here's a couple of pics for you pic hounds:

Hi, have not done a build like this but would like to at some point -- what $$ budget are you estimating for completing it (not the Hi-Po motor, just for finishing it with your 'streetable' motor)? I'm guessing $1000 to $2000 for finishing the bike 100% complete including bodywork, paint etc. (since you're a machinist and can do the work yourself). Meaning just on parts, not any labor. Close?

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