TOPIC:

I brought the frame and swing-arm home today. I was able to fit it in the back of my 1986.5 Supra and close the hatch. The frame is a lot smaller and lighter than I expected.

A bunch more brown water came out of the frame near the back of the seat tube. I looked into what to use and I'm deciding between LPS 3, Boeshield T-9, and ACF-50. Right now I'm thinking ACF-50 will be best to coat the inside of the frame, they say that it should last about a year.

Here's my checklist of things to do while I have the frame at home.

• Grind and sand everything that's left and make it ready for sand blasting/powder coating
• Get all the water out of the frame and coat the inside with Rust Inhibitor/Protector
• Wire everything up to the frame so I know how much space I'll need and where my grounds are.
• Build an aluminium box under the seat for holding the electronics
• Build a custom seat pan (fiberglass or metal). Upholstery will come last.
• Have tabs welded for rear sets.

The shop is a bit far so now that the frame is at home I can make a lot more progress. I really want to get this done and ride it.

I looked into the YZF600R forks, it seems that it has a different size front axle than the KZ1000p so I'm not sure if I could use the stock wheel. I'll need to look into it some more.

Blake, you might try Kaman bearing for the front conversion. I take old bearings to them, they measure it and hand me the ones I need. www.kamandirect.com
Steve

swest wrote: Blake, you might try Kaman bearing for the front conversion. I take old bearings to them, they measure it and hand me the ones I need. www.kamandirect.com
Steve

I wonder how the brakes would work, I doubt anything would be a direct swap. I don't think I see many people swapping their front wheels from a much older and different make bike.

Now I'm leaning towards just using new oil, springs, and maybe emulators if that's even possible on these old forks. I really like the look of the stock forks. I want this to be my "cruiser" bike that I could comfortably take long trips on rather than something all out performance oriented. I actually never had any complaints about the handling around turns or at high speeds, the suspension was just too damn bouncy. If I can cure that I'd be happy. The frame flexes and it rides like an old bike but it's predictable and none of those things slowed me down. I think putting more effort into it may be a waste, I'm not going to be scraping foot pegs on it or anything.

The YZF600R 41mm forks ( not the 43mm r6 forks) are built with a 17mm axle. The 82 KZ1000P wheel is made for a 15mm axle. My 78 Z1r, 78 KZ750B and 80 KZ1000B front wheels all use a 17mm axle. If I were building a police bike based custom I would think about using one of the earlier 17mm axle wheels. The 1980 KZ1000B wheel is good because it is wider at 2.15 in.
Good luck with your project.

I spent a few hours yesterday stripping everything else off the frame and doing some more grinding and sanding.





Here is the wiring harness that I started to strip down and everything that will connect to it.



I just got a 3rd motorcycle a couple weeks ago, a 2009 Yamaha wr250x supermoto. This is my new daily ride so I can spend more time on my projects.

the cop bike frames are sure enough stout looking !
really braced up nicely.
your metal finishing looks good.
if you are going to go glossy with the frame they have to be really smooth to keep from showing up.

i bet the daily sumo is a blast to rip around on .

keep us posted,
leon

After about 5 more hours hand filing, grinding, and sanding I'm about finished with the swingarm, the kickstand, and part of the frame. I've started spending about an hour every day after work to try to make it routine so I can get stuff finished.





Based on my progress so far I think I'll need another 20 hours before the frame is ready for powder coating. I was thinking of going blue for the frame but now I'm thinking red will look best. I need to come up with a theme so it's all cohesive. I have a lot of ideas I just need to make up my mind.

Great job on your bike! Sounds great as well. I have a 1994 Kawasaki KZ1000. I stripped off all of the cop stuff and cleaned the bike up from top to bottom. I am running drag bars with standard KZ controls. The original controls were to bulky and clumsy looking. I've replaced the stock exhaust with the 4 into one Vance & Hines, completely went through the carbs, rejetted carbs for header and intake pods.

Took me a couple weeks to clean up the wiring on the bike and to get everything electrical working as expected! I got the bike running strong, took it out for a high speed cruise and blew off the left side cover that........I searched for afterwards and never found it. That' s OK because I hated the way those covers looked. I replaced the side covers with Z1R style covers. I think they look much better!!!!
Also added the KZ tail and LTD seat. Bought myself plenty of polishing wheels from Haborfreight and polished all the engine covers. Well worth the time and effort!

Before and after pics below:





I plan on painting bike as soon as I figure out what color to go with. I also plan on changing out the swing-arm so I can run a wider rear tire.
The bike is ride-able for now so I will ride it through the summer and tackle the remaining upgrades later.

copbike1000,
you should start a thread where you can show us the modifications necessary to put the the ltd seat and tailpiece etc.on your copbike.
there are alot of guys that would like to see how you pulled it off.

an hour a day can get you some progress blakeem .
keep us posted,
leon

I Will be more than happy to do so! I will get some pics of the mods and will post so I can show you ALL the modifications necessary to put the the ltd seat and tailpiece on!

I just have to say this whole project is awesome and it's very cool to witness and see. I am actually in the process of doing the same thing but I am in the beginning. Whoever started this post and this topic I am glad you have done it. My question is how did you make that seat for it? I want to do the same thing however I do not know if it is acceptable to do this the shocks look like they go right to the front seat. I want to know if a rear seat pad is put on is it going to throw the balance of the bike out of Sku? Or are the shocks on this bike the same as a regular Kz 1000? What sissy bar did you use and how did you make that Seat? I think that is awesome.

How did you make or get that rear seat for the bike? What sissy bar did you use that actually fit on the bike ? I assume you made the seating pad but I'd really like to know how you got that sissy bar on there and what it was from. Great picture of the bike next to the boat in the garage you got an awesome set up.