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TOPIC: Doctorot's '78 KZ1000 build

Doctorot's '78 KZ1000 build 05 Oct 2011 04:20 #481447

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Ive been poking around this site for a while now. I recently realized it would be better for me to start a project thread than creating a new one each time a I had a question, so here goes...

just a little background on this bike. I bought it about 2 years ago, it was in alright condition, I rode it a bit and did a little bit of stuff to it cosmetically. I decided to ride it around the country after I graduated college. 17,000 miles later I realized I had abused it enough, and limped it home. The bike had bad compression, amongst a bunch of other problems. I decided to rebuild the top end, but once I got the engine out of the frame, I decided to go for a mild restoration, and thats when things started to spiral out of control...

here are a few pics of my baby on the trip.





I have very little experience with bikes, never rebuilt an engine. I want to try to do as much as possible myself.

To rationalize dumping thousands of dollars into this project I have told myself that it is a "learning experience". :whistle:

Here are the things I set out to accomplish:
build and convert to spoked wheels - DONE
Brace frame
brace swing-arm
seam delete gas tank - started
make custom tailpiece & seat - started
build a 1075 motor with all the best internals
motor mounts
cool shocks - DONE
rebuild forks w/progressive springs - DONE
clip-ons
rear-sets
clean up gauge cluster
lots of paint and powder.

Here is the state the bike is currently in. I have been slaving over that tail plug for over 2 months now, trying to get it "perfect". On one of my many bondo excursions I got too much on the bottom so it doesnt fit down on the frame anymore, but it will.


My padre was nice enough to let me move all my crap into his garage. Its nice to be in a garage that locks, has good light, and doesn't have a small stream run though it every time it rains.

Anyway, I have bought ALOT of stuff, and winter is typically slower for me work-wise, so hopefully ill get to put in some time soon.
-Vic
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'78 kz1000 LTD long term project

'80 kz750G project

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78 KZ1000 build (I'm learnding) 05 Oct 2011 11:16 #481481

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cool bike, i like the wheels, where was photo 3 taken? why clip=ons? are you building a cafe racer?
the trouble with you is the trouble with me, you got two good eyes but still dont see...
jerry

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78 KZ1000 build (I'm learnding) 05 Oct 2011 11:21 #481482

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That looks like the road to Roosevelt Dam in AZ. If it is, that's quite a ride for a street bike and tires.

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78 KZ1000 build (I'm learnding) 05 Oct 2011 15:54 #481523

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looks like you are off on the right foot with your rebuild.
do you have any plans of making any of those seat/tailpieces for sale?
what shocks do you have?
keep us posted,
leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0

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78 KZ1000 build (I'm learnding) 05 Oct 2011 23:55 #481609

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purple_haze wrote: cool bike, i like the wheels, where was photo 3 taken? why clip=ons? are you building a cafe racer?


first off let me say, nice avatar, im a big fan of TPB myself.

second, photo number 3 was actually taken in Big Bend National Park TX, but fxdl made a great guess considering photo number 2 was taken on the road to Roosevelt Dam.

I dont really think its going to be a cafe racer, I mostly want clip-ons because i like the clean triple clamp look, however i do like me some superbike bars as well. I think im going to try and make my own clip-ons that look something like THIS probably with a bit less rise though.
-Vic
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'80 kz750G project

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78 KZ1000 build (I'm learnding) 06 Oct 2011 00:01 #481613

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theres probably a couple KZs floatin around sunnyvale :)

them are some wicked clipons, never seen anything like that before, looking fwd to seein how this turns out!
the trouble with you is the trouble with me, you got two good eyes but still dont see...
jerry

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78 KZ1000 build (I'm learnding) 06 Oct 2011 00:11 #481617

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531blackbanshee wrote: looks like you are off on the right foot with your rebuild.
do you have any plans of making any of those seat/tailpieces for sale?
what shocks do you have?
keep us posted,
leon


I wasn't planning on selling any of the tailpieces, mostly because I assumed people wouldn't be interested. You have to cut all the seat tabs off the frame to fit it. Once i finish the mold if someone is interested in one, it would be pretty easy to pop and extra one out. I basically just took the KZ tail and made it slimmer and shorter. heres a better pic.


I also picked up this sportster tail light that fits in there quite nicely.



the shocks are Works "billet dirt tracker" shocks, I had them powder the smaller spring white.
-Vic
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'78 kz1000 LTD long term project

'80 kz750G project

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78 KZ1000 build (I'm learnding) 06 Oct 2011 00:33 #481618

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I was able to make some preogress today. I got my tarrozi rear-sets on, looks like its working out right despite what the guy who sold them to me said. although i did somehow manage to loose the bolt that connects the master cylinder pushrod to the linkage :whistle:

I also got the cases and frame drilled out to accept the pingle motor mounts i bought, forgot to take some pics of the cases in the frame before i took them out. and got my new 530 sprocket on the wheel.
Hopefully tomorrow i will start masking my cases (for the third time) to be painted. just got them back from the blaster, half bead half granite, they have a nice tooth on them.
-Vic
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'78 kz1000 LTD long term project

'80 kz750G project

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78 KZ1000 build (I'm learnding) 06 Oct 2011 09:14 #481666

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What about them wheels? 18# front and read? Where did you buy the rims and spokes and what kind of hub did you use? I'm looking for something similar on my Yamaha SRX-6....

Looks nice and keep up the good work! :)

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78 KZ1000 build (I'm learnding) 16 Oct 2011 00:17 #483454

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Mookachacka wrote: What about them wheels? 18# front and read? Where did you buy the rims and spokes and what kind of hub did you use? I'm looking for something similar on my Yamaha SRX-6....

Looks nice and keep up the good work! :)


I have a 18 x 2.50 front 18 x 3.50 rear. I bought the rims and spokes from Buchanan's wheels, the hubs I used were from a 77 KZ1000A which were pretty much plug and play. When i was reading up on building wheels allot of people seemed to discourage people from doing it, but I found it relatively easy once I had the spoke pattern figured out. After, I took them to a local wheel builder to make sure I had done them right and trued them correctly, and everything checked out.
-Vic
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'78 kz1000 LTD long term project

'80 kz750G project

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78 KZ1000 build (I'm learnding) 16 Oct 2011 00:27 #483456

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I finally got my engine parts painted. I had to wait for my new LVLP paint gun to arrive (which is awesome!) and get 240v power out to the garage for the oven, which proved to be a major PITA. I decided to go with the KG Gun Kote in satin black. I am very happy with the results it seems very tough. I did an "abrasion test" with a screw driver on my starter cover plate and it wouldn't come off at all, unless i really dug it in with the corner of the tip. Definitely a lot more resilient than the PJ1 I originally sprayed on and would scrape off with my fingernail.

I also finished up the tail piece and got it sanded down with 1000 grit so its ready for a mold, going to go pick up some tooling gel coat on Monday so I can start on that.

I suspect that my swing-arm may be bent, Is there a way to determine if it is?
-Vic
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'78 kz1000 LTD long term project

'80 kz750G project

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78 KZ1000 build (I'm learnding) 16 Oct 2011 00:45 #483458

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Looking good! Keep the pics and progress coming :)
Southern Maryland, USA

1980 KZ250 LTD (traded, but still missed)
1982 KZ750 E3 (Cafe Project) (Dyna-S, Dyna Coils, V&H 4-1, K&N Pods, 6 Sigma Jet Kit, Acewell Computer, Woodcraft Clip-ons, Custom Rewire)
1966 A1 Samurai (Restoration Project)

Wish List:
KZ1000 P (For a "touring" bike)
Z1 (need I...

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78 KZ1000 build (I'm learnding) 16 Oct 2011 13:13 #483525

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pull the rear wheel and put the axle back in and get behind the bike and look forward while trying to line up the axle with the pivot bolt.if it is off they wont line up square and your eyeball will let you know.

other wise take the swingarm off and lay it on something flat and get the measuring tools out.some vee-blocks and long straight rods would help also.

hth,
leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
The following user(s) said Thank You: BlackZ1R

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78 KZ1000 build (I'm learnding) 16 Oct 2011 18:07 #483559

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Cool little tail piece/seat pan! Is that a KZ1000 tail or a Z1/KZ900 tail? The sportster light looks like it belongs in there B)
FRANKEN Z!
1978 KZ1000 A2A with 08'Speed Triple SSSA and '06 GSXR1000 front end

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78 KZ1000 build (I'm learnding) 16 Oct 2011 20:58 #483620

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Looks like u are off to a great start. B)
What year sportster is the tail lt. it looks like a nice fit. B)
76 kZ, frame gusset work,1200CC.Ported by Larry Cavanaugh,This email address is being protected from spambots. You need JavaScript enabled to view it., 1.5mm.over intakes,.ZRX12 rear end,and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg,Ont.Can.

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~ (k) / (z)

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78 KZ1000 build (I'm learnding) 17 Oct 2011 00:47 #483681

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The tail piece is the stock KZ1000 i just made it slimmer and shorter.

As far as the tail light goes i guess it isn't a sportster. I found it at a local bike salvage place that also sells some of aftermarket parts mostly crappy EMGO stuff, I was just wandering around the hundreds of shelves of parts looking for a light that would fit in the tailpiece nicely, and I found it in a box marked sportster lights. It didn't have any packaging or tag so the guy sold it to me for $20. After cruising around the internet I believe it to be this aftermarket HD fatbob light.
-Vic
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'80 kz750G project

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78 KZ1000 build (I'm learnding) 17 Oct 2011 21:00 #483855

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So I a bit confused right now, back when i was ordering parts for my bike I looked the engine VIN up on zedder.com and determined I had a 1978 engine. looking at my Clymer manual, it says that the nuetral detent arm, which i have, is only on 1979 and later models. I went o bikebandit.com to look at some of their engine diagrams and noticed the shape of my detent arm is the same as the 1980 A4. A guy I had do some work on the bike long ago told me that the engine was a 1980, but the VIN says otherwise. Can anyone shed light on this? Is there a way to tell just by looking at the engine?



i also noticed one of the side of this bolt was bent in so i decided to bend it back, (bad idea) and it snapped off. the bolt still holds the spring on it fine. do i need to track down a new one of these?
-Vic
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'80 kz750G project

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78 KZ1000 build (I'm learnding) 19 Oct 2011 15:50 #484150

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Is your bike an LTD ? Looks like you've got a 79 or 80 motor there - MKll style countersprocket cover ,squared ends on the valve cover and the tranny door cover in the pics of your shifter is MKll or J style not Z1. Count the teeth on your camchaincrank gear - Z1's had 15 teeth(and were used in some 79 LTD's) MKll has 16 teeth. Can't tell from your pics but if they are MKll cases there will be a reinforcing fin on the top case half running behind the engine serial number boss to the cases near the pcv cover.
79 KZ 1075 MKll
79 KZ 1500 MKll dragbike
Gone but not forgotten:
3 X 73 Z1's
1 X 74 Z1A
1 X 75 Z1B

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78 KZ1000 build (I'm learnding) 19 Oct 2011 16:36 #484158

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like jack mentioned everything about your engine looks like an 80 model.it has the rib behind the oil fill cap.

what does the vin on the engine say?

leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0

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78 KZ1000 build (I'm learnding) 19 Oct 2011 17:48 #484167

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well it has 16 teeth and the fin behind the VIN so i guess it is an MKII.

The bike is registered as a 78 LTD and that checks out with the frame VIN. The engine VIN is KZTOOAE-068033 according to zedder.com that puts it in the correct range for a 78. So strange.... glad I have that figured out though. From what I have gathered the MKII is a better engine so i guess thats good.

-Vic
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'78 kz1000 LTD long term project

'80 kz750G project

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