'76 KZ900 (ZRX1200R) Build

NakedFun wrote:

Drooz wrote: Wow!! :woohoo:

I been away from kzrider for a little while. You continue to go in new directions and set new standards with this build!! Love this bike! :kiss: Very nice work here sir!!

You are too kind, but just building a bike the best I can with what I have available! Your bikes are fantastic and I am looking forward to your mono build.

Cory

Haha! You over estimate my builds Cory!! I think we all know where the flaws/mistakes are with our own builds. At least we know what we'd do differently!! Mine is pretty basic compared to yours!!

Your KZ has the "balls" that my bike is missing. That's where the future lies with mine.

Drooz wrote: .......Your KZ has the "balls" that my bike is missing. That's where the future lies with mine.

Dont't tell my wife that or those will be in her purse as well! :woohoo:

Cory

NakedFun wrote:

Drooz wrote: .......Your KZ has the "balls" that my bike is missing. That's where the future lies with mine.

Dont't tell my wife that or those will be in her purse as well! :woohoo:

Cory

Haha! :laugh:

So a quickie....

My new inverted levers got here. Decent quality, but you can see some short cuts are taken.

No bronze bushing, a non-shouldered pivot bolt, casting numbers imbeded, etc... Overall not bad for a $32.00 set. Will replace all hardware with SS Allens, a shouldered bolt with lock nut, and will machine a bronze or brass bushing (maybe a ball bearing) for the lever pivot. Will also attempt to aluminum braze weld in the recessed part number so it can be sanded and polished smooth. Either way, can't wait until I get to fitting these and the remote master cylinders....

Cory

Like to see them mounted. Never seen levers like them.

So I started playing with the levers.... First I wanted to see if the cheap castings could be accurized and take a half decent polish.

Stock was on the right and the attempted polish is on the left.

Then I focused a little more on the pivot. Lots of filing, then sanding 280, 400, 600, 1000, 1500, and Mother's polish. I also reamed the pivots and added the correct SS, low head, shouldered Allen and fitted my bronze bushing. Alot more precise, smooth movement.

Then it was time for some aluminum brazing....I wanted to fill in the cavity with part numbers and Alumiwled came to the rescue.

Then some rough filing......and then sanding......

Finally a rough polishing.....

Now my issue is one I thought about before I started. The braze alloy is different enough from the ccast lever that they polished differently and leave a polished "shadow". I might have to end up either chroming or "chrome like" powder coating. Thoughts?

Cory

very nice work. I get a little anal retentive over things like that too. if you can change it easily later, wait and see if you care when the bike is on the road. if it still bothers you then you could easily address it. Im trying to follow my own advice right now as well :whistle: , I get to hung up on details and then have trouble making progress. you seem to get hung up on details and keep making progress. Whats your secret?

[edit] are the same on both sides. could you flip sides and have that face down?

Nope, the Chinese decided to mirror the levers so boss and P/N's on both sides.....

Cory

DoctoRot wrote: ... I get to hung up on details and then have trouble making progress. you seem to get hung up on details and keep making progress. Whats your secret?....

I forgot to say I have a very loving wife that keeps my focus on getting this bike built! I am a very anal rentetive person, especially with things I create. I end up probable at a ratio of 100:1 hours of thinkin' to hours of doin'. My bike is currently sitting at my dad's shop 90 miles away, so i only get to work on it every other weekend for about a day and a half so, during the week is when I keep going over pictures and making drawings and thinking it through. It keeps me productive. Then again the $$$ is the main driver of my progress. Trying to get ourselves debt free and control spending by selling other car and bike parts to pay for my KZ parts. Once all the heavy fabrication work is complete, the bike will be blasted apart and I can finish the work in the garage at home, so it should go faster then. The main road blocks in the near future are the costs for paint ($800-$1100) and engine work ($2200).

Cory

your gonna get there cory keep up the good work man!!!!!!!
:evil:

leon

So Saturday was a lesson in 10 lbs of crap in a 5 lbs bag.... First off, I decided to create my dual remote mount.

The levers were a PITA to weld. I don't have access to TIG, so I have to MIG the 3/4" x .125" lever to a 1/2" - 16ga DOM tubing. They were so small, that I had to clamp the grounding clamp in the vise and then use the grounding clamp to hold the lever for welding. The welds look ugly, but have great penetration which is what I was looking for especially since my front brakes and clutch will depend on it..... I'll clean them up, but forgive my weld appearance this time around.... The pivots work great and smooth with the bronze bushings.

So now it is time to figure out where it would fit.... With the coils in place, it had to go directly behind them. This worked, however I then noticed there would be no way to pull the valve cover with it in that position, so you would have to remove it to do valve shimming. So it ends up the final resting place is under the seat, above the battery box.

The cables I will order will just follow the back bone of the bike and connect under the seat. The one down side is the custom HEL brake lines I ordered from Dave. The one now has to be ordered in a 20" longer custom length or put a junction under the tank and run a second line to the master. Thoughts? Extend the line or order new custom length?

Cory

Uh, did I miss the explanation of why dual remote mount thingy? One is for the clutch and one is for the rear brake or something?