1978 KZ1000 A, Mild Mods

Project is moving along, although much more slowly than I'd like. This "simple" GS conversion has been alot more difficult than I thought it would be. I've pretty much had to do everything I would have with converting any other swingarm...nothing has been "bolt on". Here's a shot with the wheel installed:



The upper shock bushings were the wrong size so I had to press out the old ones and I installed a pair from an old set of KZ shocks I had. The rear brake bolt hits the swingarm (where the brake pedal bolts to the brake rod that goes to the master cylinder) so I bent the tab on the pedal and will reverse the bolt because the castle nut is smaller than the bolt head and gives me a little more travel before contacting the swingarm. I had custom SS braided brake lines made up for the whole motorcycle because a dual disc conversion is in the plans for the front. Got all (4) lines custom made for under $100. Also did the final trim on the inner rear fender to clear the swingarm and brake arm mount. Few more pics:

Modified inner fender:


I added a few spacers to move the top of the shocks out a little more since the GS swingarm is wider:


Couple shots with wheel, shocks and caliper installed:




Also had to shim the brake arm to the KZ caliper:

Started installing the new 530 chain and sprockets. Got the trans cover cleaned up:



Got the brake line installed with a gold anodized banjo bolt at the caliper....will use the same on the front calipers when the time comes.

I have the wheel perfectly centered in the swingarm and guess what....the sprockets don't line up! I think the wheel was laced a little differently than factory even though I used a stock KZ hub. The rim seems to be a little offset to the right. This would normally be great as it would help the chain to clear a big fat tire, but I chose a 3.5" rim with a 150mm tire so I wouldn't have any clearance issues. Now I have to align the sprockets, so I have ordered a 1/4" offset front sprocket. Yep, another part of this simple bolt-on mod.

A general question to everyone....what on earth is this weld nut for? I have owned several bikes now that were 100% original and I haven't seen it used for anything. I used to think it was somehow used for the stock airbox or tool tray but it isn't. Anybody know?

chassis ground ??????

leon

531blackbanshee wrote: chassis ground ??????

leon

I don't think so, I've never seen anything connected to it. I'm thinking something used in production somehow? Maybe to hold the frame or something?? I don't know?

I'm thinking this. When they ship them they somehow use this to anchor things down in case things get rough on the ship? I know that they need to secure things down and that is the best guess I can proffer.

I bet if we saw them in the box before they were assembled that mystery would be answered.

Got my new 1/4" offset sprocket the other day. The quality is excellent....especially considering the price. I bought it directly from PBI sproskets and it was under $50 shipped....18 tooth, 1/4" offset. Really nice and was just the right amount of offset.

Do you guys know if the stock sprocket cover will fit over a 1/4" offset sprocket? Maybe I"ll have to remove the sound insulation?

Not sure why it double posted!
Well, can't delete it, so here's another picture:

I'm running stock cover with 1/2" offset, 18 tooth with 530 zz2 drag chain, the cover had to be cleared near the back where the chain rubbed. Can't see it when it's on.

Les Holt

79MKII wrote: A general question to everyone....what on earth is this weld nut for? I have owned several bikes now that were 100% original and I haven't seen it used for anything. I used to think it was somehow used for the stock airbox or tool tray but it isn't. Anybody know?

Yeap the previous owner of my bike had put the ground wire there. I moved it down to the block where it goes and the chrome (10mm headed) bolt was already down there where it was supposed to be.