FWIW, I wouldn't tackle the swingarm swap unless you have access to a lathe, or a generous sole who has a lathe. There will be plenty of new round parts fabricated in this swap, along with handy mockup parts to check fit before cutting the actual parts. However, you're ahead of the game by having a matching wheel and swingarm. As Doug mentioned, look at the project threads to get an idea of how the swaps were tackled with other arms. The process will be similar. The new arm will need to be bushed to fit your pivot bolt at a minimum. You may need to narrow the new arm to fit between your frame. Once you have the arm mounted, throw the wheel on so you can project the chain line forward to the output sprocket. This will probably show you need more offset than there's room for without modifying the frame. Then look at the Cush drive to see how much room you have to shave off, paying attention to the chain not rubbing the tire. Before I cut anything I mocked it all up based on my dimensions. Spaced the wheel over the amount I planned to remove from the hub, and spaced the output sprocket over so I could double check alignment. Then threw on a chain to triple check with my eyecrometer. Maybe more work than necessary but I hate throwing scrap parts across the shop screaming in disgust.

Take measurements and make drawings. Plan out what you want to cut and fabricate and keep track of the dimensions. One part change ripples through the design more than you know. Try to think far ahead on each part so you don't box yourself in the corner. Above all, you want solid parts built to last. The last thing you want is a bike you're afraid to ride.

Alan

Thanks for the kind words everyone. I really enjoy riding the bike as much or more than looking at it.

BTW, before the side cover and tail section repaint/striping in August, I rode this bike from Omaha to Jackson Hole, WY and back. Some of you may recall from the KZ Rider Flag Relay threads. I swear the bike ran stronger each consecutive day on the trip.

The KZ has been returned to mostly original condition. The only mods of any consequence are to the chassis; Race Tech for springs and Works Performance Steel Tracker shocks. If anyone has the same year KZ and are interested in these shocks(they can be chromed), the swing arm is a different length than later years. I was the first to have shocks made confirming dimensions. Let Works know you want the same shock as their customer, Forrest White. PM me if any are looking to improve the handling of your KZ. I believe it is the single best upgrade/mod one can perform on these vintage bikes.

Thanks again to all the advice & positive feedback during the last 4 1/2 years!

SeattleKZ wrote: Cool thanks man. Unread skittle but of this thread and saw that aligning all that stuff can be a challenge but it's good for me somebody already did it.

If you ping Leon (531BlackSheep) I think he is making a shaft I designed to slide the ZRX swinger in place in the KZ chassis. Just need to slice about 1/8" off the right hand side of the swinger pivot tube and push the seal in until it is flush. Slide this shaft in place and run two grade eight 5/8" bolts in from either side and your done. Then comes chain alignment....

Cory

Current state.

Its always easier if you have both the GSXR and the KZ in the garage side by side.

I did not have that luxury so that you can compare measurements easily. I do have a good friend with a ZRX so we did a great deal of measuring before we started the swing arm swap.

I have seen a few KZ's with the Gixxer motor installed, it seems to look reasonable. Winter is coming it is time to start on the KZ project again. Ten years now I have been working on this thing.

ok on how to insert a pic......thx
So started on taking apart the donor bike and ran into a locknut on the chain side of the swingarm.
I was ablout to remove the main nut and the bolt but the locknut on the left seems like I need a special socket to remove it.
Any Idea.......tried a flat screw driver and tap it but did not turn.
Donor is a 93 gsxr.

congrats on finding a good swap candidate. I think the older gsxr were some of the longest usd forks you could get.try and locate a member by the name black banshee. pretty sure he may be able to help you with a stem swap?as far as the swing arm first measure the frame width at your swingarm pivot bolt.with axle and wheel set into place try and locate swing arm at tire center line. you will either need to remove material from swing arm and or have some bushings made. also will need bushings made to fit over your stock pivot bolt.that bolt will need to fit swing arm.from there there are options for rear shock mount.for easiest conversion I would suggest using as much of the gsxr components together.wheels, axles ,brakes, master cyliders, rear sets,etc..good luck. and take your time.pretty much anything is possible. just look around this site. there are some pretty nice examples.

Crap...just lost a logn post !

Anyway...thanx for all the nice words.

Here´s some pic´s of the last days progress.

Old swing arm attaching brackets.



Made some new bushings to center the new bolt.












Drilled two new holse to make the rear end 1 inch higher.



New oilfilter installed



Yellow paint marking that bolt is tightend propery.

Do you mean swingarm bushings ?

Patton wrote:

GPz550D1 wrote: Ed, actually the old front sprocket was worn a bit more on the inside, although not to the extreme as the one in your picture. I wonder about alignment and appreciate your thoughts. The chain adjuster parts are the same on both sides, according to Kawasaki.com. I have some problem getting the adjustment set just right, as my old eyes have trouble seeing the marks on the swing arm real well. Thanks!

Sometimes the swing arm marks aren't entirely accurate.

Alignment may be verified by assuring that the same measured distance exists on both sides of the bike between center point of the swing arm pivot bolt and center point of the rear axle.

Where feasible, may also sight (from rear of bike) down along the top run of the chain as it leaves the drive sprocket and mounts the counter shaft sprocket.

The alignment should be absolutely straight as an arrow, with zero defection as it leaves the drive sprocket, with zero deflection between the sprockets, and with zero deflection as it mounts the counter shaft sprocket.

Good Fortune!

Carefully measured today and as you say, the swing arm marks/adjuster slots are a little off. Makes me feel stupid that I have been riding this bike for 25,000 miles with things in the drive train not lined up right. No telling how much extra wear that takes out of the chain/sprockets and rear tire. Thanks!