76 KZ900 upgrade

I just finished sand blasting my cases and zx9 brake calipers’ got my trees for a test fit and to fit the stops. Here is a pic of the trees so far. lots of finish grinding and polish work to do yet. i had the gauge supports cut off the old kz tree and welded on the zx9 tree.
The KZ stem is smaller OD than the ZX9’s. So the stems must be swapped to allow the use of the zx9 tree’s.
Just remember that the zx9 stem has a circlip in the bottom. You can’t see it as it is inside. You could turn or grind it down first. Then you must press the stem out from the top down. I found this out the hard way. My machinist pressed it out with out removing the clip. We did not know it was there. It did work though.
The KZ stem can be pressed out from the bottom up, after grinding off the weld on the bottom..
He put the zx9 stem in the lathe and drilled a hole in the bottom, the size of the KZ stems bottom OD. Then he cut the bottom off the zx9 stem. This bottom piece will act as a sleeve, and be pressed over the bottom of the KZ stem. The KZ stem can now be pressed into the zx9’s lower tree. I then drilled and tapped through the stem, and tree. I put a bolt through the stem and tree just as a precaution.

Call me crazy, but I have a KZ 900, KZ650, and a ZRX1100 and I'm messing around with all three of them. I guess I must be smarter than everyone who has worked at Kawasaki for the past 35 years. Or maybe that's dumber.

madderkaw wrote:

Call me crazy, but I have a KZ 900, KZ650, and a ZRX1100 and I'm messing around with all three of them. I guess I must be smarter than everyone who has worked at Kawasaki for the past 35 years. Or maybe that's dumber.

Wait til ya see my zrx 1100 in a couple of more weeks....:woohoo:

Shit!

These thread I just have missed. :blush:

Nice work.

I have to study closely your pictures. :woohoo:

What paint did you use on that big bore barrel?

Dupli-color Engine enamel 500*F,260*C. Low gloss black. after 1 season it has held up well.

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i guess i wont have to worry about wiping it off in the morrning then , since thats not my bike.lol.
that is 1 i saw on the net that had a big flat spot on the bottom of the header. this made me beleive i should go with the longer zx9 forks.

Man, looking good- riding it yet?

not yet. I sent my head to Larry Cavanaugh for a tune up. i should see it back in a week or so.Then vroom vroom.

I had a little extra time since i desided to send my head to the master ,Larry Cavanough.
www.flowbenchtech.com/porting/CRH/index.htm
for a tune up. so ive been tinkering a bit.
I added fittings for an oil temp gauge. i bought a mechanical type . i learned afterwards i could have got a nice electronic digital 1 for not much more. Oh well. in my next life i guess.

i had spent some time polishing the outer edge of the rim, but after i desided to paint my forks black i thought the rims would look cool in black as well. so out came the spray can .

Hear is the front end. I'm please with the way the fender turned out. It’s a zx6. I did quite a bit of carving on it to try and reduce the bulky look and get a little old school shape to it. I’m not 100% sold on it but I think it should get me by without looking out of place until I find "the 1" . What do u think? I would really like to have an Ltd style to keep with the old school kz look.
Dumb, I just noticed in the pic that since I changed the forks to black the head lt bracket should be black too. Maybe it will look better with the tank on. More red that way u know. We’ll see? That’s 1 nice thing about spray bomb. I can play with it till I get it right, and then spend the money on a good paint job later.
I used a zx12 master cyl, i have a spare if interested, and a spare kz 1 also. With the zx master there is a brake light switch so u don’t need the kz 1 at the splitter.
I used the brake line splitter so I could use my current brake lines. I just bought these lines last season .so new lines and no splitter are on the wish list for next year. If anyone is interested in buying these, and the rear let me know. They are Russell’s with clear plastic coating. I have a long pair for use with no splitter in blue as well.