76 KZ900 LTD Streetfighter build

Finished up the mono shock mount today. Shaved the rear hub so its ready. Now back to finishing the offset sprocket. Waiting on the front rim to come back from Will's Rim Repair. Then once it's all back together I can get an idea of how much drop I need on the upper triple clamp.

Sprocket is complete and ready for welding. Thanks Leon for the tip about torching out the center. I tried to just open it up on the lathe, but got to a point it just wouldn't cut and was destroying inserts left and right(they're not cheap!). After torching out most of the center it cut like butter.

a little late sorry, but what I would do is:
1- have it in gear then
2-step over and put alot of pressure on the rear brake and
3-get a floorjack handle on the end of a ratchet handle with the correct socket on it then
4-dont break your hernia back open
installation is reverse of removal
an alternative approach to stepping on the brake may be to put a screwdriver in the hole of the rotor(probably ruin something though).

A brake to step on would have been handy. Since the master cylinder mount was removed puting it all back together was not an option either. The offending sprocket is in the photo above, or what's left of it now. Took heat to get it to move, and still required about 3' of cheater, in gear and the chain trick.. I wasn't watching the chain and it took off a small chunk of the transmission housing in the process. Oh well, it's nothing structural.

Alan

Haybus wrote: Sprocket is complete and ready for welding. Thanks Leon for the tip about torching out the center. I tried to just open it up on the lathe, but got to a point it just wouldn't cut and was destroying inserts left and right(they're not cheap!). After torching out most of the center it cut like butter.

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I like what you have done here... Luis

Bunch of little, but important stuff. Welded all the side cover tabs back in the right places. Electrical panel back where it needs to be. It's the little stuff that takes forever.

Made some adaptors to locate the ZX10R rear sets. I like where it puts my feet, but will have to ride before really knowing. Obviously I'll have to limit the up stroke of the kick stand.




Had to space out the rear rotor. That ZX6 swing arm is quite a bit wider than the ZX10 was. Weird since it would have used a narrower rim. Anways the caliper bracket wouldn't engage the anti rotation block on the swing arm. I machined the spacers to receive into the hub and engage the shoulder bolts that hold the rotor in place. The bolts were about 2 times longer than need be so there's still over 13mm of thread engagement. Should be good, even though I don't ever use the rear brake. Also machined new bearing spacers as I moved the wheel over about 4mm for chain alignment.



The tire looks fat.



Sprocket welded together. Probably throw the motor back in so I can verify chain alignment and clearances now that the back end is buttoned up.

Haybus wrote: I'm ditching the ZX10 swingarm and bought a ZX6 instead. Would be too much chopping to fit that big wide swingarm between the frame. And not very practical for mounting dual shocks. Also picked up a lower triple for $34. Rear wheel looks to be in great shape but the front is toast. I thought it just had damage in the bead but it's bent beyond use. Calipers and rotors seem fine though. I like those 6 spoke wheels so hopefully one turns up for a decent price on CL or Ebay.

You had me scared there for a second. I have the 07 R1 swingarm which uses a 6.5" wheel and I never thought to measure the shock mount width distance. But now a sigh of relief. Center to center on the KZ it looked like 10 5/8 and on the swingarm I can get the tabs welded to around 10 3/4 center to center on the swingarm. Not sure if its kosher or not to put a washer in between the frame and the shock to then widen that distance. If so then I could get it the same.

Touched up pic 4 ya....was really dark.

Hollywood, I was refering to mounting the shocks to the upper brace because it's not very symetric. I saw how you're shaving down that R1 swing arm to fit between the KZ frame, and that just wasn't practical with the ZX10 swing arm.

4TheKZ1000, thanks for shedding light on my pic. Reminds me how much I hate that seat.

The seat pan is in great shape, and obviously fits the frame very well. Has anyone reshaped the foam and recovered with a non LTD cover? Or is it better to spend the extra $ and get a complete replacement? Do they fit well or need tweaking?

Alan

alan,
glad i could give you some useful advice to help you out sir.
the offset sprocket looks good.

i have spacers on my upper shocks mounts to get the shocks to come in line after i put the 6.5 inch wheel under the back of my z1r. no problems.

leon

Been busy cleaning up the engine. Got some of the nice bits painted today. Messed up the clutch and dyno cover so will have to sand them back down. VHT aluminum and clear, baked at 200f for an hour.They're super shiny, but it doesn't show up that well in the pic. Hoping to paint the rest of the engine tomorow, but depends on how much longer I have to spend cleaning. Lots of nooks to scrub and rough up.



Should have my front rim back from Will's Rim Repair this week. What a great guy. Then on to the upper triple fab.

Those motor covers look great. Should be easier to keep clean also.
Wayne