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TOPIC: Saving a '81 KZ750-E

Saving a '81 KZ750-E 08 Nov 2019 16:25 #813726

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As my rear brake disc bolts soak to get the rust off, I painted the center of the disk. The stripped bolts will get the heads painted black.



I managed to get one of the front discs bolted up, but I ended up having two of the used bolts break with the correct torque when trying to install the second one. Now that I am getting really good at drilling out bolts and extracting them, I threw in the towel and ordered all new bolts.

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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 08 Nov 2019 16:31 #813727

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Nessism wrote: 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.


I am in northern Nevada, near Lake Tahoe. There is a huge amount of mountain roads to ride in a very short distance from my home. It will be a fun weekend bike for sport riding. I will probably not put it on the track, but want it capable to do it.
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'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 09 Nov 2019 14:55 #813752

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To get the angle correct on the steering stops I need to get the front end assebled and the tank back on. Sitting on the new tires (temporarily) for the first time.

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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 09 Nov 2019 15:15 #813753

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Ran into a small issue. There is a stock bracket welded to the steering head that gets in the way of the Honda upper triple clamp. It has to get cut off, so everything needs to come back apart.
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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 09 Nov 2019 16:15 #813757

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From the picture, that looks like a perfectly viable steering stop that just needs to be narrowed a bit.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Saving a '81 KZ750-E 09 Nov 2019 17:03 #813759

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It's hard to see in the picture, but the contact area was not enough for a stop. Just enough to interfere.
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'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 09 Nov 2019 19:43 #813764

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Ahh
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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Saving a '81 KZ750-E 13 Nov 2019 16:41 #813965

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I installed the clip ons for the first time to check the clearance at the fuel tank. The fore/aft angle feels comfortable, but I would like to push them more forward. That can't happen due to interference with the upper tree clamp bolt.

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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 13 Nov 2019 16:49 #813967

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'81 KZ-750 E1
'86 Suzuki Savage 650
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Saving a '81 KZ750-E 13 Nov 2019 17:57 #813969

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Skidmark wrote: I installed the clip ons for the first time to check the clearance at the fuel tank. The fore/aft angle feels comfortable, but I would like to push them more forward. That can't happen due to interference with the upper tree clamp bolt.


use counter sunk screws?
-Vic
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'78 kz1000 LTD long term project

'80 kz750G project

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Saving a '81 KZ750-E 13 Nov 2019 18:50 #813971

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Maybe a pan head or dome head would give some extra clearance.
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'81 KZ-750 E1
'86 Suzuki Savage 650

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Saving a '81 KZ750-E 14 Nov 2019 08:35 #813991

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Another option would be to grind some relief notches in the risers. I would prefer not to go that route, though. Different bolts will be the first attempt.
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'81 KZ-750 E1
'86 Suzuki Savage 650

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