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Testarossa's 78 KZ1000 Fighter Build 09 Feb 2010 08:30 #347401

  • mark1122
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My experiance told me that if the crank and rotor are scored bad, they will never lock together.the rotor is softer, so it will likely be the worst.the big problem is that it can screw your whole summer. if u need to replace the crank, u need to pull the motor and split the cases.
i would be tracking down a spare crank now, if u feel the crank is scored.
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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Testarossa's 78 KZ1000 Fighter Build 09 Feb 2010 18:28 #347492

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i ran into this problem along time ago i tried to use a rotor from a 900 on a 1000 crank it spun after about a week i then looked a little closer and found they don't have quite the same taper. i went diggiong thru all my stuff and found the right rotor that actually came off the crank in the first place problem solved. the difference in tapers wasn't much but it was enough.
1973 z1 2-1974z1-a,2-1975z1-b dragbikes1015cc+1393cc, 1977kz1000,1978kz1000,1981kz1000j, 1997 zx-11, 2000 z12r,1428turbo nitrous pro-mod and a shit load of parts thats all for now leader sask.,CANADA
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Testarossa's 78 KZ1000 Fighter Build 10 Feb 2010 04:24 #347527

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I'm surprised that no-one has spotted my non-standard fuel tank yet. It's from a KZ750, and I made it fit by welding in a piece of 3/8" bar across the underside of the top frame tube. I had to cut off the original mounts on either side of the frame. Also had to take off a sheetmetal boss near the back of the tank. Pictures to follow.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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Testarossa's 78 KZ1000 Fighter Build 10 Feb 2010 14:19 #347593

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testarossa wrote:


DIY fork spring compressor.



."


Now is see what u mean by the 750 tank. when i saw it before, i thought it was an LTD tank.
How does the new spring compressor work? will this replace the spanner socket hook wrench, some how?
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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Testarossa's 78 KZ1000 Fighter Build 10 Feb 2010 16:48 #347612

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Mark,
The 750 tank was too cheap to pass up on ebay for $50. I like the extra capacity, and that thing is clean inside. Zero rust. I didn't realize at the time that I would have to make so many mods to make it fit. However, I have discovered that I like fabricating, so no worries.

On to the spring compressor. Your correct, it replaces the hook idea and will actually work on more modern forks. That metal sleeve is usually made of plastic on the newer bikes and that hook would do damage. Anyway, two bars that stick out of the hex are hollow and have pieces of 3/8 round CRS that slide in/out. Basically you slip the hex over the top of the fork and slide the bars into the two holes in the sleeve (where I had the hook before.) Press down with your hands and slide the keeper tool(not pictured) under the bottom jamb nut on the dampner rod. Then you have an easy time disassembling the two jamb nuts. I'll do a similar pictorial to the teardown when I put the new seals in my newer fork.

One thing to keep in mind for everyone whose running an upside down fork. Get a FSM for that bike and read up on the service interval for your fork oil. Usually, you'll have to change oil every couple of riding seasons, and you need to get the springs out to properly fill the oil. So you need the fork tools even if you never have a seal leak.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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Testarossa's 78 KZ1000 Fighter Build 10 Feb 2010 21:18 #347674

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That is gonna be one Bitchin' lookin ride when its done!B)
If you cant fix it with a Hammer....... it's gotta be an Electrical problem...

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Testarossa's 78 KZ1000 Fighter Build 11 Feb 2010 05:18 #347700

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Martynbiker wrote:

That is gonna be one Bitchin' lookin ride when its done!B)


Thank you sir! I sure hope that your right. I'm shooting for subtle with excellent craftsmanship. Personally not into the super shiny, 100% chrome, bling bling bikes. I can appreciate these, but not my style.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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Testarossa's 78 KZ1000 Fighter Build 11 Feb 2010 12:07 #347740

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What is the fuel capasity of the kz750 tank? it actualy looks smaller than a kz1000 tank in the pic. thats why i thought it was an LTD tank.
The kz1000 is 17 liters and the LTD is 13 or 13.5l, i beleive.the z1900's were something like 15 l.
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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Testarossa's 78 KZ1000 Fighter Build 11 Feb 2010 12:14 #347741

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if u haven’t already, u should put the output shaft in the cases, and mount the cases. this will give u a chance to see how the 2 sprockets are lining up. u may have to do some clearancing on the frame for the chain. the chain may rub on the inner part of the lower footpeg mount. also depending on the offset u run, u may need side clearance. with a 1/2" offset, u will clear the frame, but 5/8" will require some work.
Your swingarm may even have an offest that is not noticeable. Its worth checking.:side:
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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Last edit: by mark1122.

Testarossa's 78 KZ1000 Fighter Build 11 Feb 2010 12:23 #347742

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Mark,
Good points on checking the clearance. I'm very close to doing this. What size chain are you running? I was thinking of using a 530. I need to get a chain and sproket set. As far as the fuel capacity i'm not sure on the exact size but it definantly has more volume.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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Testarossa's 78 KZ1000 Fighter Build 11 Feb 2010 13:30 #347752

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i currently have a 5/8" offset 630.
it has worn out, so i am switching to a 530.
the 530 gians u a wee bit more clearance, even though they are suposed to be the same width as a 630.
if u need to go 5/8" i can help guide u through the snag points.:side:
76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

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Testarossa's 78 KZ1000 Fighter Build 13 Feb 2010 16:17 #348112

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Thought that I should post some progress pics. I started working on the frame braces today.



Here you can see the top tube braces and the tank mount that I added.







Here's one the lower braces in progress. I plan on adding a cap piece, and putting in a cross hole with a one inch tube like the Sanctuary frame.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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