1981 J model Endurance racer

Today was steering stem day. I did not try and cut the ZX7 stem flush, so I pressed it out and cut it too long.


Then I machined it back down to the correct dimension

I pressed them together and got this item, ready to install

Pressing the new stem+bushing into the ZX7 lower tree was going great......UNTIL....the dreaded SNAP!!!. I thought I had the tree supported correctly, but I was rushing to get home and I screwed up. This is what 40 tons does to an off kilter triple tree


Whoops. Good thing I am going with ZX9 forks and the triples are the same, so I get another chance.

ZX7 Forks too short.... Worked just fine for me... All 96 ZX7 suspension. The answer found when you take the forks apart, look at what you have, stop and think for a minute....there's length to be had if you look carefully. Then look at the top tree for some more length....3/4" to be had between the two if you look closely and apply common sense.

When you're done you simply use the stock, built in adjustments to setup the forks. They're not going to work with the same settings as a 750 with 150lb rider but there's a ton of adjustment there to dial them in. At least there was on the 96 7R forks I used. There are ride height adjusters built in. Not All years had that.

good 'ol Ebay. new bottom tree on the way for 13 bucks shipped !

Speaking about the fairing shape: perhaps a cut along the horizontal arc above the blinker? If done correctly it would be 900SS-ish.

yes i think that is exactly where it needs trimmed :evil: !

keep us posted,

leon

Back to it.........

New lower tree arrived. Got the stem pressed in with no problems this time, But something was bothering me. The top triple has a tiny bit of slop at the top between the ZX hole and the KZ stem.

I chucked the ZX stem in a lathe and bored out the inside of the top, past the threads to the outer diameter of the KZ stem. Then I band sawed the threads and the portion I needed off to make a tiny spacer. (it isnt pressed in yet because I need room to put the adjusters in first. Since the KZ item bolts from the top, it should work out OK.



from broken to faboo in 17 easy steps

glad you got it worked out.having to bush the upper triple to fit the kz stem is pretty common in these front end conversions.
here is a zx10 upper i had to do.





leon

man, if I had only not lost the bearings, there would have been a groovy photo of installed forks. I guess it is for the best because one should really always put in fresh All-Balls whilst one is at this point.

I am just hoping that I do not have to machine the little ridge that is concentric with the new stem to allow enough upward movement to make it work. It is ridge that the bearing will sit on that is 2 or 3 mm high at the base of the stem. My guess is that it located the inner diameter of the ZX7 bearing. Has anyone machined this off? or run it as-is.

as it sits, I looks like I will only have enough room for one of the adjusters, not the 2 used on the KZ. Is this typical?

timmythecop wrote:
I am just hoping that I do not have to machine the little ridge that is concentric with the new stem to allow enough upward movement to make it work. It is ridge that the bearing will sit on that is 2 or 3 mm high at the base of the stem. My guess is that it located the inner diameter of the ZX7 bearing. Has anyone machined this off? or run it as-is.

got a picture of the area you are talking about?

leon

small steps.........
I am going to use the ol "half Kawasaki bracket/half weld on bung" technique. Everything is placed well and seems to be in a good place.


I think I have located where the fairing must be. Very scientific.


I wish I had a welder here. Oh well, baby steps.....