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TOPIC: Saving a '81 KZ750-E

Saving a '81 KZ750-E 28 Oct 2019 10:08 #813164

  • Skidmark
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That is what I was thinking...
Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 29 Oct 2019 11:40 #813223

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More gusset work. A bit tricky getting the fit right, but two pieces make it easier than trying to do a wrap around with one piece.

Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 29 Oct 2019 12:38 #813225

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It's more fun ruining cardboard instead of metal. Cheaper, too!

Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 29 Oct 2019 18:22 #813242

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Started big, then decided not to align with the centerline of the frame tubes.might add some holes to keep air moving onto the cylinder head.

Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 31 Oct 2019 20:46 #813353

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I had the new tires mounted up. Metzeler Roadtec 01's.

Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 01 Nov 2019 08:43 #813376

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So the powder coat shop I am working with told me they would prefer the steering head bearing NOT be in the frame when they coat it. The issue I have with that is I need to install the bearings so I can assemble the front end and fab up my new steering stops. I think I will tell them they just need to mask them off well. Once installed, I am not going to ruin them by pulling them back out, and I need to finish all of the welding before the frame gets blasted and powder coated.
Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 01 Nov 2019 10:45 #813384

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Instead of a cross brace behind the carbs/under the seat, I decided on a single cross tube. It's placed close to the mid point in the frame between the engine mount points and the frame junction at the rear of the fuel tank.
Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 01 Nov 2019 15:19 #813399

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I want to use a "superbike" style handlebar, but the CBR600-RR front end uses a clip on style handlebar set up. I decided on Woodcraft riser clip ons, with a 3" rise. They arrived today, and I think these will give a better control position that the stock Honda clip ons (I didn't get the bars with the front end).

Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 02 Nov 2019 03:53 #813422

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Why not putting risers on top of the top triple tree. Drilling and taping the top to fastning the raiders, or welding for that sake.
Brgds Anders

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Saving a '81 KZ750-E 02 Nov 2019 08:02 #813434

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I did not like the idea of having the bars mounted by bolt through the thinnest part of the top triple tree. It is cast aluminum, and I do not have a TIG welder (and have never learned how) so I would need to pay someone to weld it for me. Add the time and expense of fabricating or modifying handlebar clamps. Since this build is a bit of a resto-mod with the modern front end, it was an easier solution to use off the shelf parts.
Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 02 Nov 2019 12:12 #813451

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What ever works for you. I got to like the superbikes bars a lot, as you got the ĺeverage to stop a slight wobble to turn in to a tanks slapper.
/A

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Saving a '81 KZ750-E 02 Nov 2019 12:36 #813452

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The last piece of the front end puzzle arrived today. This will stop those little wobbles from turning into tank slappers.
Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 02 Nov 2019 13:25 #813456

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Skidmark wrote: The last piece of the front end puzzle arrived today. This will stop those little wobbles from turning into tank slappers.


Looks familiar!!!!

The best choice you could have made for a steering damper!!!!

Looks like the very same damper I used on my RG.
1972 H2 750 Cafe Racer built in 1974.
1976 KH400 Production Road Racer.
1979 Kz1000 MK. II Old AMA/WERA Superbike.
1986 RG500G 2 stroke terror.
1986 GSXR750RG The one with the clutch that rattles!

Up in the hills near Prescott, Az.
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Saving a '81 KZ750-E 02 Nov 2019 14:19 #813461

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By reversing a bar clamp, I preloaded the lower front engine mounts outward .25" before welding.



After welding in the gusset plate, it came back right on the money. No change in distance! Lucky beats good every day of the week!



No, I don't weld the prettiest, but I get good penetration.
Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 02 Nov 2019 14:25 #813462

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Skidmark wrote: No, I don't weld the prettiest, but I get good penetration.


theres a joke in there somewhere.

nice work.
-Vic
_________________________________
'78 kz1000 LTD long term project

'80 kz750G project
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Saving a '81 KZ750-E 02 Nov 2019 15:17 #813465

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All of the bracing is finished. Now on to the steering stops and damper mounts.

Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 08 Nov 2019 15:56 #813721

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I have been working on the new design for the steering stop. I had a couple of ideas, but went with the simplest design. There is a round post that extends down that the stock lower triple tree would contact with two cast tabs. I ended up welding a .25" thick x 1.00" steel flat bar on the end of that post - the edges with contact the outer edge of the Honda lower triple clamp. Sorry, no pictures yet. I will post some when I remember to bring my phone to the shop! :blush:
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Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 08 Nov 2019 16:06 #813723

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Looks like you have added a good bit of metal to that frame. What is your intended usage? It should make a pretty stable road racer.

Not sure if this link will work but this shows where the old skool racers guys used to brace the GS1000 frame (which is one of the better handling UJM's.) Brace point C is one of the more critical so you may want to go after that if you still have a hanker'n to add more.

kzrider.com/forum/attachment/90696
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Saving a '81 KZ750-E 08 Nov 2019 16:12 #813724

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There is still more grinding and fine tuning on the angle to be done, but I am happy with simplicity and strength.

Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 08 Nov 2019 16:17 #813725

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I would like it to be a capable track day bike, with a vintage superbike theme. I will ride it, keep it for a while, then probably sell it to help fund the next project (what that may be God only knows!). Originally I wasn't thinking about bracing it, but when it was brought up it made too much sense not to.
Retired gearhead
Minden, Nevada
'81 KZ-750 E1
'86 Suzuki Savage 650

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