Testarossa's 78 KZ1000 Fighter Build

I don't really know why it seems that way. maybe it has something to do with the distance between the front sprocket to frame and rear to tire? or maybe light rubbing on the tire just doesn't show up ware marks on the tire?:side:

Giving this some more thought, i think that when u get off the gas the chain slack heads forward . this is likely why the frame gets hit and not the tire.

Streetfighter, thank you. I never thought about them screwing in.

Thane, I have definantly been checking out your build. Love the bike its tough. FWIW, I would go with a nice flat black. It looks right on your bike. So how many teeth on that rear spocket? Are you happy with your gearing?

Mark, don't waste your money sending that sprocket, I'll sort it out.

So I have been a total lazy-ass when it comes to the bike this week. Work has been less than fun, and Cub Scouts is kicking my ass. Also had to help the wife pick out her new toy-1997 Miata. She lets me have two motorcycles, so I guess I am obliged. Anyway, I was able to resurrect my old PC. Low and Behold, I found some pics of my KZ when I brought it home.





Too bad I don't still have a picture of the tail-light with the Playboy bunny sticker. It really completes the look. My favorite was when my son asked me if I was keeping the "Bunny rabbit sticker." He was about 5 at the time. I don't think he's ready for me to explain the context.

It looks like a fairly clean complete machine when you started. I wish I had had the forsight to take a few pics when I brought mine home. So then not much progress since you helped source a pink Miata?

I guess that you could say that it was fairly complete. No exhaust, rusty frame, really rusty seatpan, rusty wheels, brakes stuck, but it had compression and a title.

Not a pink Miata, but close. Its red and very loud. Someone had the foresight to mount a glasspack in place of the original muffler...WOW! I must say that the little car is Bloody fun to drive even with me having to squeeze my 6'3" 235lb. ass in the driver's seat. Handles like a go-kart. I must say that the average American is lost when it comes to their idea of a sports car. You could try to follow me on a twisty road with your favorite Mustang, Camero, Charger, etc. and I guarantee that I would lose you with this 13 yr old 4cyl 133 H.P. girl car. I'm soo far into the corner before I have to use the brakes that you are already done, then I adjust the line and right back on the gas. I love an underdog! So how does the 914 handle since you put the SBC in?

BTW, I promise some serious progress this weekend. I forsook a ride on the Three Sisters (Central Texas Motorcycle Utopia) to stay home and knock out some KZ work.

As far as the 914 goes, lets just say it's far to easy to scare yourself if you don't pay strict attention. Probably a little heavier than your miata, but not by much. The original weight bias was 48% front 52% rear. Now its 46% front 54% rear. Not as neutral handling as it used to be, but about the same as a 911 now, a little tail heavy. But I know the feeling well: with your ass 6" off the ground, speed has a new perspective. :woohoo: So if you want an idea of what driving my 914 is like, throw 200 lbs of weight in your trunk and add 250 more horsepower

So I wanna see some KZ progress buddy!

Ok, you want progress, well here you go. For starters I detailed the teardown of an upside-down fork a while ago in this thread: kzrider.com/index.php?option=com_kunena&...ew&catid=5&id=341303

Here's the new thread with proper tools and it shows the rebuild as well: kzrider.com/index.php?option=com_kunena&...ew&catid=5&id=353185

Now I also discovered that I can get my engine in and out with the jugs in place, and still have my downtube braces in their original configuration. YEEHAW! I even put the cams and the cam chain roller in place to verify that you can remove the valve cover to do lash adjustments.



I also fixed up a steering stop.



Figured out where I want to mount the rearsets, and bought the mounting hardware today. You should see pictures tomorrow if I don't get distracted.

Also got about halfway through my el cheapo tire replacement. I guess that I get what I deserve for bitching about how hard that rear was to remove. The front was EFFIN welded to the rim. I promise pictures tomorrow. BTW, I'm conducting clinical trials on the 50% acetone 50% ATF penetrating oil. I can't yet comment on its ability to cut rust, but I have three observations. #1 these two chemicals don't dissolve. You need to shake it up to acheive a colliodial suspension before you spray. #2 don't put your spray bottle in the sun. The acetone is so volitile that it self-pumps out of the sprayer when it is warmed. Messy! #3 this stuff is KILLER for breaking stubborn beads on old crusty-ass tires.

Finally, I set down and wrote out a build plan for what is left. OUCH! That is depressing. 8.5x11 two columns full!

Now thats more like it I'm jelous you have a rolling chassis, but at the same time, I know a company that can make your engine cases look better than new......
I forget Josh, did you install the forks first or the swingarm? I only ask because I was thining that I may hold off on the upper shock mount on mine until I get the forks on. That way I can level out the bike with the mount since the forks are going to be an unchangable dimension. I'm happy to see your forward braces can stay. The more that you make work, the more that I can copy :ohmy:

Forks first. You are right, that is pretty much a done deal on the ride height. You could go with one of those sick japanese gullwing upper triple clamps to raise the front, but they are proud of their creation. I just mounted my forks and then I setup the rear suspension.

testarossa wrote:

Forks first. You are right, that is pretty much a done deal on the ride height. You could go with one of those sick japanese gullwing upper triple clamps to raise the front, but they are proud of their creation. I just mounted my forks and then I setup the rear suspension.

And they're not above charging astronomical amounts of money for their pride either. I was drooling over a Ti exhaust system the other day that was :blink: $2800 :ohmy: Well, I'm on the prowl for as complete a front end as I can get, looking at 07-08 R1, that way I can get the black upper tubes, they're a little longer than GSXR forks and stock 6 piston calipers :silly:

testarossa wrote:

I also fixed up a steering stop.

A thought came to me while looking at this pic. Fist off, this is a great and simple method of making a stop.
The most pure and simple i have seen yet.Congrats on that.
I just thought it may be helpful to drill and tap the lower tree stops for an adjustable stop bolt.
Food for thought. i just love things to be veritable, Just in case.
Here is D&G's link. they have all sorts of sprockets with a nose for the support bearing.U can get sprockets cheaper elsewhere without the nose though(Pingles, Schnitz). if u find u need less than 5/8" offset, u will not need support.

testarossa wrote:

Forks first. You are right, that is pretty much a done deal on the ride height. You could go with one of those sick japanese gullwing upper triple clamps to raise the front, but they are proud of their creation. I just mounted my forks and then I setup the rear suspension.

If u are interested in gullwings. Talk to Leon (531blackbanshee). He has a keen interest in building 1 of these,himself, and has some interesting ideas and dif methods of making this happen for little cash.

As for matching the front and rear ride height. This should not be difficult, since both ends come from bikes with similarities, at both ends. Just don't veer too far from the stock geometry of the chosen rear end. the rear shock has been sprung , and valved to work at that geometry, and if u get too far away from this, the shock will not perform to its max ability.

What if i milled off the two stops that are on the lower triple clamp and replaced them with eccentrics? I know what you mean about being variable. Heck I'm not even sure if I will go with the clip-ons, or handle bars. Unlike most middle aged men, the clip-ons feel natural to me. You should try the riding position on my road-race bicycle. The hand position on the drops is a good 9" below the saddle.

Are you saying that I will need support if I go with the 5/8" offset? I'm getting ready to pull the trigger here.

As for the whole Gullwing/rideheight thing, I'm happy with my current stance until I start dragging my headers. If that happens, then I will re-evaluate. Sometimes I forget that I work at a machine shop capable of making this part. My machine is soo focused on small, tight tolerance parts that I don't even think about regular millwork. This would involve a lot of millwork, and I'm not comfortable asking the boss for that favor with the current climate at work. If I have to pay the going rate for a one-off plus anodizing, then I may be better off ordering one. Man I wish I had a Bridgeport at the house.

On the rear suspension, I measured carefully, and the mounts are very close to the stock GSXR geometry. I think that my main challenge will be the weight difference. The KZ is a good 100 lbs heavier than the GSXR, so I may have to respring and play with oil weights to get the proper dampning. It is really shocking how much you can transform the handling of a bike with suspension changes. I bet that you will become a suspension nerd when you start hitting the track with that CBR.