'76 KZ900 (ZRX1200R) Build

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!

Patton,

That HH setup is sweet! I think it'll look nice. Was considering running two, stack with a radius 2 into 1 collector into the mid pipe. Kinda like half of the factory 4 into 4. I decided against it after playing with photo shop. Like I said, will move it up like a high mount at an angle.

Anyone have recommendations or comments on the coating for the header and mid pipe? Black, silver, etc? Should I have it rechromed?

Cory

what header are you using for the front half?

leon

Leon,

I actually don't know! It was an aftermarket 4 into 1 system that came on the bike, but the can was rotted out, so I ditched it. It did not have a tag on it. I think it is a vintage V&H setup. It was chrome with almost equal length primaries. The collector is a slip fit, 2.5 OD.

Cory

so it is steel?

which means it will need coated somehow.

i am trying to visualize how it will match/contrast the stainless.

you could have it chromed and then brush it lengthwise with scotchbrite to tone it down and get closer to the stainless finish.

leon