KZ1000R1 clone project

Hi everyone,

As many of you already know, I'm looking to build an elr clone to keep company to the Z1100R1.

I've been searching all over the web to find a good post for this type of porject but didn't find anything with all the information I needed at the same place.

Well here it will be!

This will be my winter project but I'm acutaly picking all the info I can in order to have a identical replica of an 1982 model. I know it will be a replica of a replica and it will never worth the money and time I will invest in it but still, this is my passion and hobby. Some people play golf and give a lot of money only to kick a little white ball so.....

Ok here is the project:

Got a 1982 GPZ1100 and a 1981 KZ1000J. Both have an elr seat and 4/1 Kerker exhaust. From what I've found, the ELR is made frome parts of these 2 bikes. I'm using the GPZ frame since it is all in regulation. (the Kz haven't run for at least 8 years).

Usaualy, an ELR is a J bike with GPZ bodywork, oil cooler, footpeg, front brake and master cylinder and shifter linkage. The shock, seat and Kerker is unique to the ELR. Lucky for me, I've just bouth a pair of shock from a Zephyr which are the same except the color.

Since I'm using the GPZ as a base, I'll transfer the complete front end, motor, gauge, carbs, airbox from the KZ to the GPZ.

Here is the picture of the GPz. It will be completely tear down in maybe a month and send the frame to powdercoat painting.

I'll try to take the most picture I can.

Feel free to add your comments.

Tks,
Joce

I'm watchig and smiling...just keep posting the occasional picture...

Finaly starting the project!

The GPZ is now totatly strip down and all parts ready to go to the powdercoater. I'll post some picture when done.

As already mention, I'm using a GPZ1100B2 and a KZ1000J in order to build a KZ1000R1. One question for all the expert: I'm taking the fork and triple tree from the KZ and instaling them on the GPZ frame. The reason for the fork is that I want to have the air bleader on top. I notice that the brake rotor are not the same size so I'm thinkin about using the bottom leg of the GPZ (Galiper doesn't mount at the same place) and the tube of the KZ. Is this something possible? The KZ tube seem to be longer of about half an inch, will this be a problem?

Here is a picture of the KZ.

I'll try to solve this by myself.

Seem like the triple tree from the KZ grab the fork a little further than the GPZ. SO I don't think I will have a height issue.

The only thing is that the distance between the wheel is gonna be a bit longer.

I'll try to take some picture this week to show you what I mean.

For the leg fork swap, I dismantle both of them to compare and see if it's possible.

Mcdroid wrote:

I'm watchig and smiling...just keep posting the occasional picture...

Yep! What he said! BTW: cool project!

Have been pretty busy lately but here is a little update on this project.

Everything is back from the powdercoater and it's all pretty nice. Cost for sandblast and powdercoating was 200$ which I think is OK. Had near 40 part to paint.

Has you can see on the picture attached, Ive started to put everyting together. Front end was partly install last night and motor block is going in tonight. I'll try to have some newer picture soon. Glad that it's starting to look back as a moptorcycle. Was in many box a month ago!

Few questions left, I've seen a lot of people putting GPZ cams in the Kz head. Mainly on some 750 motor.

I will have the choice with some kz1000j cams and gpz. Which one should I put and why?

The motor that I will be using is a 998cc from the Kz1000J. It has the first oversize. Will be using a 4 in 1 Kerker KR with stadard Mikuni cars.

Next question is for the motor covers. I will have them powdercoat ut was wondering what do I do with the clutch cover. DO I leave the oil lever lense there? Will it resist the heat?

Thanks for your input to everyone.

Joce

jcote75:
I have some "guesses", but nothing that I know for sure. I'm guessing the GPz cams will be hotter, and who doesn't want more power!
With the motor cover, if you can source a new oil-sight-glass from a Kawasaki dealer, it can't be that much money, why not just go ahead and replace it? I mean, you're going this far and making a nearly perfect beast...just pop for the new window and you'll sleep better.

Keep the pics comin'...love it so far!
-KR

jcote75 wrote:

Everything is back from the powdercoater and it's all pretty nice. Cost for sandblast and powdercoating was 200$ which I think is OK. Had near 40 part to paint.

Hey Joce, who did you coating and what was the turnaround time?

Here is the wesite of the guy.

www.fabricationstremex.com/service.html

It is near Quebec City and does a lot of ATV.
Took 2 weeks to get everything done. Note that the sandblasting was done by another company.

The cost for the powdercoating was 120$. This is low since he wait to have a lot parts of the same color to do the job. SO you don't pay a minimum for the set up.

Other color are available but pricing and delay are different since gloss black is a common color.

The guy speak english so the best thig is to call him directly.

Here is a picture of where I'm right now!

Put the body work on to see if everything was fitting right before starting the paint job. Everything fit fine + give a good boost seing all this looking like a motorcycle again. I've receive a set of decals from the comapany "reproduction decals". Seem to be top quality. Can't wait to have them on.

Still waiting for the motor covers and bottom fork to come back from the powedercoater. Hope it's gonna be next week.

Meanwhile, cylinder and head should be install this week end. Got a few helicoil to install but nothing major (still got my finger cross).

Carbs will be doing a long trip to Wiredgeorges for rebuilt.

Everything going fine but not 100% sure it's going to be ready for spring.........

Anyway, I,ll try to post some picture more often if I can.

Thanks everyody for your help

Post edited by: jcote75, at: 2008/03/07 11:40

lookin good!keep us in the loop.

Lookin' good! Got more pics, yet?

-KR