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cafekz750's Cafe KZ750 Project 16 Mar 2008 11:57 #200362

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Well, after many years of riding KZ750's and wanting to head in a more cafe direction, I finally bit the bullet and started this winter.
I have owned this particular KZ for over 10 years now. I bought with a full Windjammer fairing, freeway bars and a sissy bar/backrest. I stripped all of those items off in a month after owning the scoot. Rode for a year with the buckhorns, only to replace them with superbike bars. This bike, with superbike bars and stock footpegs, I found to be quite comfortable. I have had 700 miles days on the bike bike pictured below. I have ridden this bike 4000 miles in 9 days on a trip through the US and Canadian rockies. But, it was time for the bikes next stage of life (I have an FJ1200 that I really like for sport-touring).
This winter I found guitargeek's post on homebrew rearsets and decided to give it a try. I should say that I have a complete parts bike that I pulled the extra bits from so I can switch back at any time in case I decide it is time for the next version of my KZ750.
Link to guitargeek's rearsets:
Ghettotech DIY punk rock homebrew rearsets
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 11:58 #200364

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I needed to replace the superbike bars and decided to go with clubmans.
Superbike bars:
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 11:59 #200365

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Clubmans:
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:01 #200366

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I was really happy that I didn't have change any of the cables or brake hose for this swap. I just removed the headlight bucket and carefully routed all of the cables and hose and it works great with no binding.
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:04 #200367

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Now for the rear sets.

The brake side is just like guitargeek's but I think I may have welded in a different spot.
Before:
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:05 #200368

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Another shot:
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:06 #200369

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Now here is the old lever and the new lever with the piece cut out for reference.
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:07 #200370

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All bolted up and ready to go.
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:10 #200371

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Here is a shot comparing the stock foot peg to the new location. I should mention that I did just what guitargeek said in his post. Remove the pin holding the foot peg and flip the bracket around and install. A little cutting and grinding is necessary, but it was easy enough.
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:11 #200372

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Now for the shift lever side. Before:
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:11 #200373

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Another shot:
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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cafekz750's Cafe KZ750 Project 16 Mar 2008 12:16 #200376

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So, instead of buying a ZX-6 shift lever I decided to make one out of aluminum that I had laying around. It took longer than I thought it would, but it was February in WI so I have lots of time. What I did was remove the foot peg bracket and cut the threads off the end of the top stud that holds the foot peg bracket. Then I used a drill press and drilled out a hole and tapped threads into it. Sorry, I used 5/16" hardware because it was at the hardware store and it was stainless.
The stud mounted to the bike (the upper of the two):
1981 KZ750H2 - V&H 4-1 pipe, pods, jetted, clubmans, homebrew rearsets, 18" rear wheel and more.
Parting out a 1982 KZ750H3 to fund future projects
2 other non-Kawasaki motorcycles
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