'76 KZ900 (ZRX1200R) Build

prolly for wideband or egt sensor for tuning. assuming its on the outside for access and removal after tuned in.

the pipe did turn out nice.

leon

Wow, missed all these comments. Yeah, that O2 bung is for my Innovate Wideband tuner. It is to the outside for ease of use. It will be black ceramic coat, so it should disappear under the bike.

So I got to do a little playing this weekend. I found that my new 18 tooth offset sprocket (last was a 17T) gave me an additional .080" radius increase. In addition, found that what I thought I bought was a 45T rear, ended up being a 42T!



So I am winning the battle of the swing clearance. Ordering a 46 tooth steel for the rear which should give me about .320" radius increase and even more clearance. Here are a couple of shots of the bike sitting straight up.




While I was installing my D&G Clutch Plate I found out some carnage that happened back in 1978.......




I saw that the sprocket cover had been windowed due to a faulty chain that broke in 1978 in the PO's logs. Well it took out some of the transmission cover as well.... Found a nice used one on EBay so I bought it tonight and should be doing a little better next time....

Still waiting on my brother to finish turning my rear hub, and we'll be almost at teardown time... I am going to end up using a Ducati clutch slave for the conversion. More pics to come in a couple of weeks.

Cory

looks tough man,

leon

Thanks Leon! I hope it all works out in the end. I am getting ahead of myself, but does anyone know of a conversion for the big Kz's that allow for 6 speed transmissions? Maybe a GPz trans conversion?

Cory

unfortunately, the only ones i know of go the other way. 2 or 3 speed tanys, for the drag guys.

Looking great! Love that aggressive stance.

I haven't seen a six speed conversion...would be great to have though.

Just thinking about gearing a speed limits vs. redline, etc... I know the KZ650 and 750 guys have something where they can use a GPz550 trans and get 6 speeds, but that is all I have found. My ratio should be 2.55:1 so it shouldn't be too bad. Should be comparable to my ZRX with its 5 speed and its gearing.

Cory

Ok, so I need a sanity check. I figured on, and found that I will need to replace the R&R & stator on the KZ. With that, I stumbled on this thread a couple months ago:

www.kzrider.com/forum/2-engine/548404-ex...al-alternator#550952

The belt drive system is really trick. I like the slimer profile of the engine, and I happen to have gotten a Nippo Denso 40 amp alternator with built in R&R for free. This thing is TINY and should work well. I want to keep the starter system intact as well. So I think I can make this system work although it will take some significant design and machining work.

If I use a D&G dyno cover plate and crank nut, then seperate the one way clutch from the stock charging rotor, and machine a tube & flange assembly that would bolt in place of the rotor and attach to the starter nut which contains the taper to fit the crank. The major machining issue would be I would need to make a dyno plate "spacer" that would resemble the gasket only about an 1" thicker that would allow the cover to be spaced far enough off the engine to permit keeping the starting components. This would be the toughest part to make. The machined tube and plate from earlier would protrude trough the cover and seal against an output seal. Then simply taking the drive nut and machining it down and welding either a plate or the drive pully directly to it.

The rest is simply a bracket that would hold the alternator and make a manual tensioner.

Am I looney to try this? It would be cool and would allow alternator replacements simply down the road?

Bueller?

Cory

don't look back cory!!!!!!!!!!!!!!!!!!!!



do it !!!!!!!!!!!!!!!!!!

:evil:

and then show us the pics !!!!!!!!!!!!!!!!!!

leon

Gee thanks Leon! You are not a sanity check but an instigator! Means I need to buy a 18lb plate of T6061.....

Cory

OH YEA !!!!!
That looks like a fun project.
i would like to play the spoil sport though.
i say get her up and running, then start this a a new project.
I cant wait that long to see this baby running.
Then i'll look forward to the devilish new project. :evil: