Got her on the road!

Hello,
I joined last summer when I bought a 79 KZ1000. I bought it off ebay. The bike was represented in the ad and by phone conversation as 4400 miles, stored for 20 years and a frame off complete restoration as just being completed. "Ready to ride cross country" the guy said. As soon as I heard that phrase I should have know better LOL. I drove 4 hours to pick up the bike and the frame off restoration was clean out the gas tank and spray bomb some rust on the frame! The tires and chain O rings were shot, paint was bubbling up on the tank, fork seals leaked, rear shocks locked up, carbs gummed up, etc. The good news it only had 4400 actual miles and still had the break in sticker on the tach! I beat the price down and bought it anyway. I called in a favor and had a friend repaint it. I repalced shocks, front fork seals and springs, new tires, installed a 1075 overbore kit, ported my head, K410 cams, BS34 carbs, new chain, shortened the turn signals, lowered 1 inch, well you get the picture. Finally got the jetting close today so I am ready to ride! Best of all I know my bike inside and out.
Will P in NC mountains
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i53.photobucket.com/albums/g55/exitpupil/DSC03439.jpg

Will congrats on a really nice job. That bike looks fantastic, I always liked the 77-80 LTD 1000's. I'll get another one before it is all said and done. With the low miles and all the work you performed that 28 yr. old Kaw should last another 28 yrs. no problem.

I see you worked out how to connect the BS 34 carbs to a factory airbox, seems to me someone was asking about that in the last week or so here, you may want to enlighten us here how you did it. I think you are going to enjoy this summer big time.

To use a factory airbox with BS34 carbs I bought a 750E Kaw airbox and boots from ebay for $18. The airbox WILL NOT fit into the 1000 frame. I used the boots though. I usd the 750 airbox to trace the hole pattern then used a dremel to enlarge the 1000 airbox boot holes. The two inside holes don't match up perfect, leaving about a 1/8" gap, but the boot barley covers the gap. If you were concerned silcone could be used to fill the gap. Lacking the airbox as a pattern the holes are equal distant on the 750. The 1000 airbox requires removal of the spark arreator screens and most of their attachment materal inside the airbox as well. So just open up the holes and use the 34 carb boots. I switched to a K&N filter for the airbox too.

if anyone wants the hole tracing I could mail them one.

Nice Will, thanks for sharing:)

Nicely done.

Are those Sportster shocks?

What kind of paint did you use on the lower forks?

Hey, got any pics of the port work on your head?

Wow, simply beautiful!

Does the exhaust pipe (Mac I believe) have to be removed to change the oil and filter?


With all that work, I bet she really moves!

Exitpupil wrote:

Best of all I know my bike inside and out.

EXACTLY!! Great job, man! Enjoy the ride!

I do not have to remove the exhaust to access the oil filter.

The shocks are KZ 750. They are 1" shorter than stock so I dropped the front forks 1" in the triple tree. The shocks (Progressive) came with bushings to adapt to my frame. I did have to cut a small piece out of the chain guard for clearance on the shock.

I have no photos of the porting. However I followed Larry's advice in the engine forum. He posted photos. He did the calculations for my bike and gave the deminsions the ports should be. I followed them almost exactly. When I CC'd the port volumes I ended up going about 1 mm over his ideal recommendation, but still in the parameters, to get the volumes equal (my inexperience). His advice to go slow can't be overemphasized.

Post edited by: Exitpupil, at: 2007/03/13 11:09

Post edited by: Exitpupil, at: 2007/03/13 11:28