TOPIC:

Salut,
Four years ago i bought a 1980 Kz750e and wanted to start riding a different style, i am used to ride racer. So got the bike home fix the brakes, exhaust adjusted a few things to get it rollin.
At first i got use to the bike heavier, braking, handling were not like the bike i used to ride. I like the feeling of that bike .My wife was working evening shift at that time, so i've put some miles on that thing. I started a list of what needed to be fixed, and what a list it was. I have looked at project that some of you had done, and realy got inspired, the bikes were well done and so beatiful to look at. 
Sudently an other bike came across, same bike but diferent year a 1981 all original an nothing missing, and way fewer things to do, so went and bought it.
When i got home i decided to go for a ride and at the same time check it more closely, the bike would not start, the starter clutch died right there, no warning sign.
Got the bike to the operating stand and this is were i've learn few tricks about Kz750 engine from you guys. Not gonna tell everything that i've done to the bike but if you want you can look at my first post ''New Member'' there is a couple of pictures. Bike was repaired, but at that time i had too many, so sold the 1981 Kz, easy sell it was almost like a new one.
During that time the '80 Kz was waiting... I did not want to just fix the bike, i wanted a project.
Wanted a more reliable and durable engine, better suspension, more braking power, and with the same '80s look, not a Café Racer, a custom bike.

This is were i started.

 

So how does the bike look now ?

Sorry for keeping you waiting,
This is a list of the modification that were made.
1- Front suspension, wheel, brake of '94 GSXR 750
2- Complete engine and exhaust from a 2002 ZR-7s 27k km
3- Delete air box with short velocity stack
4- Rear swing arm, whell, suspension, brake from the same 2002 ZR-7S.
5- 3'' clip-on riser from Woodcraft Technologies 

More pictures will come on how it was done, with details.

Oh yes! 

looks great.

was the zr7 engine a direct fit ?

 

Hi JR
No not direct fit but close enough to get started
To ease the fit i got an empty engine case and the transmission shaft to locate where the chain will be
First had to remove the lower motor mount that were welded on the frame.
on the left rear side up and down of the ZR7 engine it was the same as the KZ. So there was my first clue.
For the right rear side i use washer as shim to fix the engine so i can work on the front mount.
I did not use the ZR7 rubber mont for the front i used the solid one from the KZ.
 

But it did not ended there...
The output shaft on the ZR7 is longer than the KZ. So i needed an offset sprocket to fit to the chain to the rear sprocket.
I had a spare Kz transmission and compare it to the Zr7. The gear have the same ratio but not the same shaft. and the outer roller bearing were bigger on the ZR7, i tried the KZ output shaft assembly with the outer bearing of the ZR7 and it fit like a glove, probleme solved.

Then had a flash, If i can fit the rear monoshock suspension and rear swing arm of the ZR7 i could fit a bigger tire!!!!
I took some measurment on the ZR7 frame and the KZ to see if it will fit and i saw a glimse of light, that was enough for me.....



 

First look at the rear set up

Fitting the Swing arm, The bolt from the ZR7 is too big and the inner shaft too long, so before drilling and cutting... Measuring!!
The outter tube  from the KZ swing arm is 34mm what a coincidence so is the outter bearing race on the ZR7 
 I cut the tube from the KZ swing arm, and clean everything smooth, cut the ZR7 tube in the middle hone the bore and fit the tube.

 

Ajusting the swing arm on the tube before welding

After welding

Swing arm is in, and look good !!!