'76 KZ900 (ZRX1200R) Build

i stopped by
hotshoecustoms.com saturday so my wife could buy another shirt,and he had this bad boy cbx loaded up headed to new york city.



last time i stopped by his shop he was in the middle of the build,it has a cool undertail exhaust.

as with anything it can look good if done"right".

i have faith that you can make it work out cory.

can't wait to see whatcha come up with sir.

leon

The Aprilia SXV's have a sweet undertail exhaust with nearly side exit, slash cut tips. Those big cans hanging off the rear fender kill the look for me.

So due to a employee chosen extra holiday, I had some time to go an putz with KZ. Didn't get much accomplished though. The things I learned today...

1. Undertail exhaust will not work......I would have to custom design a very low profile, single muffler. I don't want to mess with the rear profile/height/shape.... So back to the second wonderful idea (insert sarcasm where you need) for exhaust.

2. Love the rear sets by Les. May have to decide if it is worth it to move forward with trying to keep the kick starter and mod it to work with the rear sets.

3. Moving forward with my own custom wiring harness.

4. May leave the stock kick stand as I think the additional lean is OK and may be beneficial toward the stability when on its stand.

5. Making new mounts for the oil cooler. Going to be rubber mounted at 4 points.

Repaired the battery box and got it installed to make sure everything fits together nicely. Here are some pics of the rear sets.




More from this weekend......

Cory

NakedFun wrote: To answer the previous questions:



2. The front required the stock KZ stem be swapped by machining a reducer bushing that adapted the OD of the KZ steering stem to the ID of the ZRX original steering stem hole. In addition, the top ZRX triple had to have its steering stem hole enlarged from 18mm to 28mm to fit the top of the KZ steering stem.
visually to fit the theme of the bike.


I think that was all the questions? :woohoo:

Cory

All I did to make the ZRX triples fit was call "all balls" bearing guys and we figured out what I needed to make the ZRX triples & stem work in the Z1 steering head. It all fit perfect.

Chris

o.c.f.rider wrote:

NakedFun wrote: To answer the previous questions:



2. The front required the stock KZ stem be swapped by machining a reducer bushing that adapted the OD of the KZ steering stem to the ID of the ZRX original steering stem hole. In addition, the top ZRX triple had to have its steering stem hole enlarged from 18mm to 28mm to fit the top of the KZ steering stem.
visually to fit the theme of the bike.


I think that was all the questions? :woohoo:

Cory

All I did to make the ZRX triples fit was call "all balls" bearing guys and we figured out what I needed to make the ZRX triples & stem work in the Z1 steering head. It all fit perfect.

Chris

Hey Chris, that's awesome. Do you have any part numbers for the bearings that you used? No mods to the stem at all? Thanks

That's interesting as I know they carry adapter bearings, however I noticed there is a significant (.25-.3") length difference in the stem heights between the ZRX and KZ. Maybe not so on your older Z1?

Cory

79MKII wrote:

o.c.f.rider wrote:

NakedFun wrote: To answer the previous questions:



2. The front required the stock KZ stem be swapped by machining a reducer bushing that adapted the OD of the KZ steering stem to the ID of the ZRX original steering stem hole. In addition, the top ZRX triple had to have its steering stem hole enlarged from 18mm to 28mm to fit the top of the KZ steering stem.
visually to fit the theme of the bike.


I think that was all the questions? :woohoo:

Cory

All I did to make the ZRX triples fit was call "all balls" bearing guys and we figured out what I needed to make the ZRX triples & stem work in the Z1 steering head. It all fit perfect.

Chris

Hey Chris, that's awesome. Do you have any part numbers for the bearings that you used? No mods to the stem at all? Thanks

Just go here: www.allballsracing.com/index.php/forkconversion

Select the proper drop downs for your chassis, and use the chart to select the correct top and bottom bearings. This doe not account for changes in the steering length though.

Cory

So I am a slacker. I spent this past Saturday playing on our hunting and camping property with my family then working on the bike! I got my Polaris RZR out of storage for the first time in like 9 months! Anyway, got some stuff done on Sunday.

1. Designed and fabbed up my oil cooler mounts.
2. Fabbed up my rear sets "specimen cup" mount.

The oil cooler mount is rubber mounted with shoulder screws on top (wrong length in the pic) by a 1/8" plate that is drilled and tapped, then welded at the bottom of the neck plate. May still add a very slight gusset from the lower tabs to the frame tubes.




The stubs on the rear frame tubes that I cut off to fit the ZRX swinger, I was grinding down and cleaning them up, when I decided to use a 8mm coupling nut, and welded into the RH upper frame stub to mount the cup off the frame near the rear set. Just had to cut the stock supply tube down. Due to the zinc coating/nut material, the welds were not pretty, but I dressed them up and should look OK powder coated.





So with that, I ordered up my exhaust components. Stainless 12" megaphone with a 2.25" inlet & outlet. Going to make a custom mid pipe and do an S1 high mount configuration. Should wail....



Trying to decide if I should make the mid pipe and header into one? Then the only connection would be at the muffler. Would be like my ZRX. Also, should I ceramic coat in black or silver? Should I just coat them in black high temp paint? Going to leave the SS muffler alone though.

Also, some "bling" showed up today! :woohoo:

Fork Brace



HEL Lines in Green and Gold




I am also going to go with clip ons. I am bidding one some now. So anyway, still making progress....

Cory

NakedFun wrote: Fork Brace

What's the make of the fork brace?

Greg Couch. Can be found the ZRX forum or he sells on Ebay.

Cory

lookin good man :evil: !

leon

Handsome reverse cone megs!

Reminds of the Hooker Headers, which once were available in 4>2 and 4>1.





Good Fortune!