Testarossa's 78 KZ1000 Fighter Build

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18 Apr 2010 19:00 #361554 by porchev914
Replied by porchev914 on topic Testarossa's 78 KZ1000 Fighter Build
How much trouble would it be to make new footpeg parts with knurls? You could take the easy way out like I did and adapt another bikes rearsets, but I think you're set where you're at. I don't think my Lincoln mig is even rated to as thin as 24 guage :P

FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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18 Apr 2010 19:07 #361556 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Not too much trouble, and I made the rearsets to accept standard GSXR footpegs. I may just go that route.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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18 Apr 2010 19:34 #361566 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
So I started to go thought my wiring harness and I think that my head is going to explode. It would definantly help to have a factory service manual here. That wiring diagram in the Clymer manual sux. Got everything sorted, but I have a coulple of questions.

It seems that I have a ton of extra blue and brown wires. Now the blue wires appear to be hot wires for the running lights and the brown is hot with the key "on" and seems to power things like indicator lights on the dash, the horn, and the flashers. Is it ok to remove the extras? Or am I missing something. These wires all terminate at the end of the harness that is inside the headlight.

Also there is a connecter that doesn't seem to have a mate anywhere. It has a green and a grey wire with a space for a third. It is also located in the headlight. What should plug in here? Here's the plug in question.




1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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18 Apr 2010 19:52 #361570 by JakeB
Replied by JakeB on topic Testarossa's 78 KZ1000 Fighter Build
It looks like you're right about it not plugging into anything. I just took a look at the diagram in the filebase, and it shows a 3 pin connector with a gray wire and a green wire going into it but not connected to anything. :huh:

Hopefully somebody knows why there is an unused connector.

1978 Z1-R

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18 Apr 2010 20:08 #361573 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Damn! I wish that I would have thought to look in the filebase for the wiring diagram. That is a million times better than my Clymer manual. Maybe its a one size fits all wiring harness or an accesory connection. Looks like I can chop it.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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19 Apr 2010 17:06 #361768 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Since I was such a lazy ass yesterday, I decided to get a little work done today. I finished my repairs on my exhaust. I had to cut four slits in the can to be able to remove the baffle. It was rusted in place. Today I welded up the slits and did a little body work to straighten out the can.

Here's the slits. I have been reluctant to show these for fear that Tony might kill me for mutilating his old exhaust.



Got em welded up and ground down.



Now a touch of high temp paint to keep things from rusting.




1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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19 Apr 2010 17:10 #361770 by T_Dub
Replied by T_Dub on topic Testarossa's 78 KZ1000 Fighter Build
Sure that looks like new! Nice work. I gotta do the same with my yosh.

1977 KZ650B1
-810cc
-Cavanaugh Racing Head
-Mikuni RS34's
-GPR Muffler

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19 Apr 2010 17:12 #361771 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Yesterday, my son wanted me to remove the "pegs" from his bicycle. Today I thought that I might be able to re-purpose those guys, since they are already nicely knurled.





The only problem is that they are quite a bit larger diameter than my current pegs. What do you think?

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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19 Apr 2010 17:17 #361774 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
T_Dub wrote:

Sure that looks like new! Nice work. I gotta do the same with my yosh.


Thanks man. This was the easy part. Welding that baffle back together was a bitch.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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19 Apr 2010 17:21 #361776 by T_Dub
Replied by T_Dub on topic Testarossa's 78 KZ1000 Fighter Build
That'd be different looking. Why not try it out?

1977 KZ650B1
-810cc
-Cavanaugh Racing Head
-Mikuni RS34's
-GPR Muffler

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19 Apr 2010 17:22 #361777 by T_Dub
Replied by T_Dub on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

T_Dub wrote:

Sure that looks like new! Nice work. I gotta do the same with my yosh.


Thanks man. This was the easy part. Welding that baffle back together was a bitch.


Yeah I really hope my baffle is ok when I take it out.

1977 KZ650B1
-810cc
-Cavanaugh Racing Head
-Mikuni RS34's
-GPR Muffler

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19 Apr 2010 17:23 #361778 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
I just might, but I gotta get permission from the little guy. If I weld them up without telling him, then I'll be a bad daddy.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

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