CSR1000 Project Build

oh yeah !
lookin good ,keep us posted.

leon

Planned on putting the forks back together this weekend, I got everything stripped,cleaned,repainted the bottoms,polished up the nuts and bolts etc and picked up new seals,dust covers and oil.




Unfortunately,the dust seals are the wrong size (for a later model) The oil seals look ok but the numbers stamped on the edge arent the same as those on the old ones. I should have checked.
Thats my 'weekend working on the forks' out the window. Back to the shop to order new ones. Bugger.

davido wrote: Planned on putting the forks back together this weekend, I got everything stripped,cleaned,repainted the bottoms,polished up the nuts and bolts etc and picked up new seals,dust covers and oil.

Unfortunately,the dust seals are the wrong size (for a later model) The oil seals look ok but the numbers stamped on the edge arent the same as those on the old ones. I should have checked.
Thats my 'weekend working on the forks' out the window. Back to the shop to order new ones. Bugger.

Nice rear sets. I like the pegs a lot. I hear ya on the forks. Seem like anytime i go to rebuild something, halfway through I realized i either ordered the wrong part or forgot to order a part. gahhhhh

OK. A bit of progress. I got the right bits sorted for the forks,I wanted to get them back together over the holidays but
I sat on the couch watching crap films instead. Its also been a bit nippley in the workshop so Ive ended up totally uninspired.Though today,I pulled my finger out and went forth.
Its my first time doing upsy dupsy forks so i did a lot of research on the web and took a lot of photos when I stripped them,which was a good thing as I wasnt expecting such a long delay twixt stripping and reassembly. Anyway,it took about an hour and a half to reassemble the first one, get the oil in and everything done up. The second one went a lot quicker,maybe half an hour.

Special tools needed for stripping and rebiulding upsy dupsy forks.
A piece of non Kawasaki string (optional)
A genuine non Kawasaki compression tool ( I think it was originaly a washing machine spanner.I cut a slot in it)
A non Kawasaki seal driver ( A seal club?).Short piece of plastic drain pipe,cut in half

I also got the yokes/triple tree sorted. I think.
I sent the 2 sets (CSR and ZXR) off for a stem swap but he cut out the ZXR stem and turned a new stem to the CSR specs. Very nice looking. Last night I fitted the Allballs.

and today I fit it all together

It looked a bit of a dogs dinner to be honest,So, after a bit of head scratching I shuffled things around

It looks a bit better now,


So thats it for now.Im glad these bits are out of the way. One step closer to a rolling chassis. All thats left now is a pair of shocks (hard cash) and the brackets to fix them on to the swing arm. Then I can get it off the work table and roll it up and down the corridor making brumm brummm noises.

Now that is looking good

Fantastic build thread & well thought out mods.

Kudos for all the extra time not spent wrenching but documenting your process for all the other fellow enthusiasts to learn and benefit from. Looking forward to more from you!

Thanks Puffin. I am well pleased with it so far.Though Im starting to get inspired again , theres no money to push forward. The shocks are going to cost around e300 and theres no getting around that.

I was in the workshop today,cleaning up a bit and thought I could maybe have a go at mounting the rearsets. I have all the bits I need and access to a welding machine.The problem is that Im not sure how to go about it.




I suppose they need to go around here somewhere and I need to weld some kind of mounting bracket onto the frame.


Can anyone advise on the does/donts? How do I find a good position for the rearsets ? What do I need to know? Can I weld a piece of billet steel directly onto the frame downtube or do I need to weld 2 thin pieces either side of the downtube,like the original? Lots of questions,has anyone covered this in a previous build thread?
Help me out here,Im trying to get the momentum going again. Thanks.

I think the only way to find the best location is to sit on the bike, at least that's how I did it. I drilled an extra hole in the frame and used the existing one with spacers to bolt a plate and then bolted the rearsets on that. I have no idea what I'm doing so it may not even work.

If I had access to a welder I'd do it something similar to this (although not a kz1000).





On this he did similar to what you're saying and used a flat plate welded with some spacers bolted to that.





Anyway, great build and inspiration! I'm looking forward to more updates.

I had a few left over threaded bungs that I welded to the frame of my Gpz750. My rearsets are an aftermarket pair meant for a Zx12. I tried to keep the same mounting angle so the pedals would be close to the right orientation. IMO, where you held your footpegs will be far too low and far back. I made my pegs to be roughly 1" up and 1" back in the forward most middle position.




Later, Doug

Good idea boys,I hadnt thought of that.Looks a lot cleaner than welding a plate on and I held the rearsets up to get a better idea and with this method I should be able to get them further forward. I cant sit on the bike yet (to get a good position) as I still dont have the shock mounts yet. I took one of the original shocks over to the bike shop on thursday and hes going to machine some mounts up for me,then I can take them to the aluminium shop with the swing arm to get them welded on.Hopefully this time next week,I should have a rolling chassis.
So other than that,all Ive managed to do lately is re-thread and shorten the sprocket mounting bolts and get that mounted.

Not sure if itsthe right way around though theres a recess on tother side.This way brings it closer to the tyre.Other way brings it closer to the frame.Ah well,Ill sort it out when The motor is in.