Nelson's KZ1000 Fighter? build

Got the front brake all assembled and bled. It's got a good feel now. Someone was asking about this ealrier so here's pic of one of the SV650 calipers. You can see the aluminum plate I made for it. I did have to carefully grind down the boss's on the inside of the fork legs to make this work, so it wasn't quite as simple as just making the plates.

I don't like this sprocket. Look at the chamfering by the splines. It significantly reduces the engagement area between the sprocket and the shaft. The shaft barely sticks out far enough as it is, this is not cool. Crappy Emgo!! I think I bought it from Z1 Enterprises. I wonder if I could return it after having it a year or so... :pinch:

The old sprocket I took off did not have the chamfer. I think I need a diff brand. Any suggestions?

I put this stuff on today. Noticed the large starter gear does not spin freely. It has a bit of drag when I push down as shown. Before tightening the flywheel bolt it would spin free, but as I tightened it the gear started to drag. Is that the rubber damper pushing against it?

I took it apart and oiled everything then reassembled and still the same. I don't know if a bit of drag is normal. This is assembled with all the old parts I took off, there are no new parts and nothing different. Same old rubber damper.

Ideas?? :huh:

i wouldn't sweat the chamfer on the sprocket.

i am of no help on your starter gear drag tho,
sorry.

leon

I believe some drag is necessary.

Nice looking work Nelson, Kawasaki made 3 different size rubber starter gear dampeners, if you feel you have too much drag you most likely need the next larger one. You can not buy these dampeners (to my knowledge anyway) so you will need to find them used. I was in the same boat over the winter grabbed one off of a spare motor I had. I had the part numbers writting down somewhere and can find them if you need them. This is one area of the Z1 KZ motor I thought could have been designed better as its a pain to get dialed in properly.

Doug

yeah I tried to buy one a while back and could not find them. Wouldn't I need the next SMALLER one to create more clearance?

Odd that these are all the same parts I took off it... Maybe it had this drag before and I didnt' know it. Seems like too much tho. I"m afraid it will get hot and melt the edge of the damper.

I wonder if too much drag could cause the starter to turn...

regarding the sprocket - I've seen severely damaged countershaft splines on many dirt bikes. Even a little KDX200. This is not cool for a 1000. The KZ shaft barely sticks out far enough as it is.

Nelson wrote: I wonder if too much drag could cause the starter to turn...

Yes! if there is too much drag it will prevent the starter clutch from freewheeling and cause the engine to spin the starter.
I would leave it for now and see what happens when you run the bike as it may be ok after all.
You can buy the dampers from kawasaki and places like z-power etc.
If it does drag too much and you can't find a supplier then you can reduce the thickness by carefull lapping of the rubber edge on some fine wet and dry used wet.
You need to take it easy and keep test fitting the damper until you get the desired fit.

How would I know if there is too much drag while it is running? Can't see anything...