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TOPIC: Testarossa's 78 KZ1000 Fighter Build

Testarossa's 78 KZ1000 Fighter Build 26 Dec 2009 23:05 #340793

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Ok so I bought this 1978 KZ1000 A2 basketcase for $400. It had been yard art for probably 10 years, but was mostly complete. The engine had compression on the kick starter, so I figure that it could be made to run for not too much money. This not being any sort of special model, and not nearly complete enough to do an original resto I have decided to do a streetfighter. So far I have purchased a 1995 GSXR 750 that will donate a 43mm USD front end with fairly modern brakes, and a monoshock swingarm. Best of all, it will allow me to run the 120/70r17 and 180/55r17 that I want. Other good things about this particular Gixxer are that it has a cable driven speedo just like a KZ, and the swingarm pivot is narrow enough to fit the KZ frame with some spacers.




This is the quick and dirty mock-up.

Unfortunatly I can't find a pic of the KZ assembled when I brought it home b/c I recently had a little computer crisis and suffered a lot of data loss.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Last edit: by testarossa.

Testarossa's 78 KZ1000 Fighter Build 26 Dec 2009 23:30 #340794

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I plan on documenting this build so that others can use this thread as a assembly manual if they choose to use the same parts. I am a machinist by trade, and I plan on doing as much of the work myself as I can.



Here's a pic of the GSXR Steering stem. I pressed it out at work the other day. It presses out through the bottom of the lower triple clamp. Unfortunatly it's a bit short and the bearings are different sized to the KZ bits. I will machine a hybrid stem that fits the GSXR forks and the KZ frame using standard KZ size bearings. Once I know for sure that this works I'll post a copy of the print. That way you can take it to your friendly local machine shop to have one made. Or pay me to do it;)
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX
The following user(s) said Thank You: jmoney05

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Testarossa's 78 KZ1000 Fighter Build 26 Dec 2009 23:41 #340795

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Thanks for sharing...we are all watching :)
Michael
Alvin, Texas

1982 GPz750
1977 KZ1000A
1978 KZ1000A
1982 GPz1100
1975 Z2A

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Testarossa's 78 KZ1000 Fighter Build 26 Dec 2009 23:47 #340796

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Now on to the heart of the beast. I started tearing into the head today. I must say that I'm mostly pleased. My plan is to run a mostly stock motor at first, and later I want to build a very streetable Hi-Po motor. I'm thinking KZ900 crank with some 10.25/1 Pistons to bring it up to a 1075. I already scored a set of BS 34's uber cheap. I must say that the "mega torque" thread is right up my alley here.

Anyhoo, for now if the stock pieces can be reused, they will. So I am pleased to report that my cams measure good, all the valves look good, and all shims and buckets were rotating freely with no funny marks. On the bad side, I discovered that the tach drive gear is quite bent, I launched one of my valve spring keepers into low-earth orbit, and I found something wierd on my cam bearings.




What's up with those bumps on the bearing? All of the lowers look good, but most of the uppers look similar to this. BTW, the cam bearing journals are smooth. Any clues on what caused this?
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Testarossa's 78 KZ1000 Fighter Build 26 Dec 2009 23:52 #340797

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Mcdroid wrote:

Thanks for sharing...we are all watching :)


I'm hoping that you guys will give me the appropriate, well timed kick in the ass to keep moving forward. I may have to sell plasma to get this thing done, but somehow I will.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Testarossa's 78 KZ1000 Fighter Build 27 Dec 2009 06:56 #340815

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Looking forward to seeing it finished!
84 KZ550-F2 LTD
93 ZR550-B4

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Testarossa's 78 KZ1000 Fighter Build 27 Dec 2009 07:02 #340816

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"kick in the ass"... Oh hell, that's no problem here.... :blink: :huh: :dry: :P :laugh:

For the steering stem, fab up a coupler that presses into the lower tree and use the KZ stem... ;) That's pretty much how the rest of us have done it but then again, not a machinist. :blush: I'd think you'd have no problem lathing that Suzuki stem for your needs....

As you have stated, image/record/document your methods and you'll make a whole slew of new friends here... ;)

Now, more pictures damn it! :woohoo:

OMR
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az

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Last edit: by Old Man Rock.

Testarossa's 78 KZ1000 Fighter Build 27 Dec 2009 08:34 #340836

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testarossa wrote:

Now on to the heart of the beast. I started tearing into the head today. I must say that I'm mostly pleased. My plan is to run a mostly stock motor at first, and later I want to build a very streetable Hi-Po motor. I'm thinking KZ900 crank with some 10.25/1 Pistons to bring it up to a 1075. I already scored a set of BS 34's uber cheap. I must say that the "mega torque" thread is right up my alley here.

Anyhoo, for now if the stock pieces can be reused, they will. So I am pleased to report that my cams measure good, all the valves look good, and all shims and buckets were rotating freely with no funny marks. On the bad side, I discovered that the tach drive gear is quite bent, I launched one of my valve spring keepers into low-earth orbit, and I found something wierd on my cam bearings.motor sitting long time B) oopsies! if its just on top side of bearing id guess its from oil drying up from motor sitting for a long time




What's up with those bumps on the bearing? All of the lowers look good, but most of the uppers look similar to this. BTW, the cam bearing journals are smooth. Any clues on what caused this?

Still recovering,some days are better than others.

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Last edit: by PLUMMEN.

Testarossa's 78 KZ1000 Fighter Build 27 Dec 2009 08:45 #340839

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Uh Plum.... Think you forgot to add something here such as a remark to what the bumps are or a question, either way old man, you forgot to complete.... :huh: :dry: :blink: :P :laugh:
1976 KZ900-A4
MTC 1075cc.
Camshafts: Kawi GPZ-1100 .375 lift
Head: P&P via Larry Cavanaugh
ZX636 suspension
Keihin, 29mm CR specials
Kerker 4-1, 1.5" comp baffle.
Dyna-S E.I.
Earls 10 row Oil Cooler
Acewell 2802 Series Speedo/Tach
Innovate LC1 Wideband 02 AFR meter

Phoenix, Az

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Testarossa's 78 KZ1000 Fighter Build 27 Dec 2009 20:43 #340897

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OMR I had considered your idea about the steering stem, but I was concerned about the KZ stem being welded into the lower clamp. So did you grind out the weld, and then press out the stem? Which direction did the stem press out? This sleeve would def. be easier to turn than a whole new stem. A little less "Government Work" would be easier to get approved by the Boss-man.

Plummen, I must know what your comment was about my bearing pic. I have two guesses 1.)No comment-if you can't say anything nice... 2.)Hit quote button, then pass out as the unconscious finger left clicks the Submit button. I'm really dissapointed about those bearings, b/c other than those bumps, I'd reuse them. And those little buggers are kinda expensive.

Anyways, I didn't make too much progress today. Just popped off the jugs, and I'm pleased with the state of the union of the cylinder department. I also gave my work bench a nice protective coating of 10w40. I was forced to go for a ride on the zx-10r today since the weather was soo nice in Houston today.

Here's a couple of pics for you pic hounds:



1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Testarossa's 78 KZ1000 Fighter Build 27 Dec 2009 22:31 #340905

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Hi, have not done a build like this but would like to at some point -- what $$ budget are you estimating for completing it (not the Hi-Po motor, just for finishing it with your 'streetable' motor)? I'm guessing $1000 to $2000 for finishing the bike 100% complete including bodywork, paint etc. (since you're a machinist and can do the work yourself). Meaning just on parts, not any labor. Close?
1978 kz1000 A2 with Kerker
1980 Z1 Classic with Kerker

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 02:50 #340907

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As concerning the bearing. I have seen bearings with the same,as you call bumps.
I doubt they are bumps. I would make a wild guess and say the engine has probably set for a extended period in hot and humid weather and condensation set in.

I personally would reuse the bearings. Use scotchbrite to remove the bumps.

Roy
1979 LTD Street Fighter.1977 KZ1000

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 06:46 #340931

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roy-b-boy-b wrote:

As concerning the bearing. I have seen bearings with the same,as you call bumps.
I doubt they are bumps. I would make a wild guess and say the engine has probably set for a extended period in hot and humid weather and condensation set in.

I personally would reuse the bearings. Use scotchbrite to remove the bumps.

Roy


Roy,
Upon further examination, they are definantly bumps. They are in the neighborhood of 0.005" proud. I think you are spot-on with the cause, this bike sat in the Houston, Tx area for at least 10 years. It looks to me that the layers of different material are separating and pushing the top layer up. Just like having rust under your paint. Actually they all appear in areas that show no witness marks from wear. Funny to see just how out of round these bearings are. My concerns about reuse are twofold. Lack of oil pressure, and potential that the bumps cut loose and float around in the oil.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 07:05 #340934

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newOld_kz1000 wrote:

Hi, have not done a build like this but would like to at some point -- what $$ budget are you estimating for completing it (not the Hi-Po motor, just for finishing it with your 'streetable' motor)? I'm guessing $1000 to $2000 for finishing the bike 100% complete including bodywork, paint etc. (since you're a machinist and can do the work yourself). Meaning just on parts, not any labor. Close?


NewOld,
I think you are close, and I'm guessing close to the $2000 mark. What I have got so far is $400 for the KZ, and $260 for a donor GSXR. I expect to re-coup 100% of that $260 since I have a good radiator, cooling fan, subframe, most of the plastics, exhaust, motor(core), and a rough gas tank that I can sell. I'm using a 78 KZ750 tank that I got off Ebay for $50. I'll be painting so lets say $300 for supplies. $250 for various gaskets, and seals, I really want that black Kerker so $525 Yikes! New tires $300. Just that stuff adds up to $2085, but again I suspect that, in time, that GSXR will pay for itself. I will also have some extra KZ parts that will put some money to the good. I'm sure that those funds will go into things like electronic ignition, new pistons, etc.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 08:50 #340948

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This is a sweet build! B)

I almost got into a similar build a year ago, but changed my mind. It looks like you might change my mind back again!

Keep it goin'!! :laugh: :laugh:
'77 kz1000 (zx10r) Modified/Street
'81 GPz550 "TrackBike"
'05 zx10r Retro/Mod Sportbike 4 SALE!!
'02 zrx1200r Lightly Modified Street SOLD!!
'74 h2b 750 (FZ600) "Mongrel" 2 Stroke SOLD!!


"Invictus Maneo" - I remain unvanquished.

Kawasaki - Let The Good Times Roll!

Mississauga, Ontario. CANADA...

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 09:26 #340955

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testarossa wrote:

newOld_kz1000 wrote:

Hi, have not done a build like this but would like to at some point -- what $$ budget are you estimating for completing it (not the Hi-Po motor, just for finishing it with your 'streetable' motor)? I'm guessing $1000 to $2000 for finishing the bike 100% complete including bodywork, paint etc. (since you're a machinist and can do the work yourself). Meaning just on parts, not any labor. Close?


NewOld,
I think you are close, and I'm guessing close to the $2000 mark. What I have got so far is $400 for the KZ, and $260 for a donor GSXR. I expect to re-coup 100% of that $260 since I have a good radiator, cooling fan, subframe, most of the plastics, exhaust, motor(core), and a rough gas tank that I can sell. I'm using a 78 KZ750 tank that I got off Ebay for $50. I'll be painting so lets say $300 for supplies. $250 for various gaskets, and seals, I really want that black Kerker so $525 Yikes! New tires $300. Just that stuff adds up to $2085, but again I suspect that, in time, that GSXR will pay for itself. I will also have some extra KZ parts that will put some money to the good. I'm sure that those funds will go into things like electronic ignition, new pistons, etc.


Sounds reasonable, encouraging too, with the part out of the donor bike. Would love to hear the final outlay. And good luck to you, everyone here can help! Pictures welcomed too, it's very informative for those of us thinking about a build in the future...thanks. I only wish I had your machinist skills, that part I'll have to tackle when/if I decide to do it.
1978 kz1000 A2 with Kerker
1980 Z1 Classic with Kerker

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 18:15 #340996

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Monday update here. I sucked it up and finished tearing the engine down today. Pleased to say that everything in there looked good. Did have some funky thick black oil in the bottom of the pan, but zero sludge deposits anywhere. Did have two of the case bolts break off, but I'm actually surprised that there weren't more. Also, looks like the alternator rotor spun on the crankshaft. The end of the crank was slightly galled and that bugger was a bear to remove. I need to get some pics of the hidden bolts to remove before you try to split the cases. I'll try to post these tomorrow.







You will notice that the number one piston has been removed from the rod. This was necessary to remove the crankshaft assembly from the upper case half. All of the other pistons came out easily. I suggest that you remove this piston before you split the cases. BTW to remove the piston just pull the circlip out at the end of the wristpin and gently tap the wristpin out from the other side with a brass punch.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 18:33 #340998

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One more quick pointer here for removing those pesky phillips head cover screws.

Here's one of my funky clutch cover screws.



Get out your #3 phillips head screwdriver and your hammer.





Put that screwdriver in place and give 'er a couple of good wacks to get it seated real nice.



This does two things for you 1)the impact can help loosen seized threads, and 2) it swages the head of the screw to fit the tip of your screwdriver exactly.

Now without moving the screwdriver, get both hands on there, lean your weight on that screwdriver, and "Man-Up."
Remember lefty-loosey.

This really helps with munged screw heads and seized threads.
Also helps if you can hit it with some penatrating oil the day before you actually try to un-screw it.
1978 KZ1000 A2 Click--->Build Thread
1982 CB750F
2004 ZX-10R
Spring, TX

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Testarossa's 78 KZ1000 Fighter Build 28 Dec 2009 18:34 #340999

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testarossa wrote:

OMR I had considered your idea about the steering stem, but I was concerned about the KZ stem being welded into the lower clamp. So did you grind out the weld, and then press out the stem? Which direction did the stem press out? This sleeve would def. be easier to turn than a whole new stem. A little less "Government Work" would be easier to get approved by the Boss-man.

Plummen, I must know what your comment was about my bearing pic. I have two guesses 1.)No comment-if you can't say anything nice... 2.)Hit quote button, then pass out as the unconscious finger left clicks the Submit button. I'm really dissapointed about those bearings, b/c other than those bumps, I'd reuse them. And those little buggers are kinda expensive.

Anyways, I didn't make too much progress today. Just popped off the jugs, and I'm pleased with the state of the union of the cylinder department. I also gave my work bench a nice protective coating of 10w40. I was forced to go for a ride on the zx-10r today since the weather was soo nice in Houston today.

Here's a couple of pics for you pic hounds:



i got in a hurry and screwed up! :laugh: its in the middle of your post,it basically says ive seen worse so dont worry.just clean em up B)
Still recovering,some days are better than others.

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Testarossa's 78 KZ1000 Fighter Build 29 Dec 2009 14:42 #341120

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An impact driver works very well. Not to mention no risk of injury.
The Phillip head screws on these older Jap bikes are different than what most of you have for screwdrivers. With the correct screwdriver bit, there will be no marring of the screw head.
Your pointer about setting the screwdriver first is good though. You are correct in that the force will break the corrosion formed by years of aluminum to steel. When reassembling, I use a little bit of Bel Ray assembly lube. It fills in all possible air gaps and prevents future corrosion. Don't worry about the bolts loosening up in time. If you use just a little, you won't have a problem.
1978 KZ1000A2A, 1971 CB500K, 1972 CB350F, 1974 Guzzi 850T, 1974 Guzzi 850T, 1975 Guzzi 850T Hot Rod, 1966 BSA A65 Lightning, 1978 SR500

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