78 KZ1000 project

I've been looking over your site for months since I've had this bike for information so I decided to make some contribution. I traded a car for 2 motorcycles and the KZ was one of them. There has already been some work done on the bike but it seems to be the usuall swingarm and forks upgrade so I decided to do something different. I've got a GS 10" swingarm, 1996 ZX9R bike with everything attached that I'm going to rebuild the KZ with. I used the ZX9R engine/electronics for a 3 wheeler project I'm working on so I had the complete bike left over for parts.

I'm thinking the ZX rims/tires, GS extended swingarm and ZX forks/brakes, rear sets and hand controls from the ZX. I've also got a 07 GSXR 1000 monoshock for it and a KOSO RX1N gauge pod to install on it. Oil cooler kit and a 1075 piston kit. I've got all the parts I need, just need to get on doing it. Anyone have experience with putting jackshafts on bikes? I think I will need one with the new wider rim.

I'm going to make carbon fiber fenders and attempt to make the side battery covers out of carbon fiber as well. I will have to fabricate up mounts for 3" dual headlights and carbon fiber/fiberglass windsheild. New regulator/rectifier single peice and unfortunately I'm going to have to completely rewire the complete bike. Just ordered a Clymer book so I'll start in a few days. I'll be getting rid of the old parts so email me if you're interested in any of them. I'll post pictures as it goes, summer is getting close so I need to get on the project!

welcome.lotsa folks here to help.i can't wait to see what you do with the bike.especially interested in seeing the carbon fiber work.i have been wanting to re-create my z1r sidecovers in c-f.keep us posted and thanks for joining.where abouts in north cakalacky are you?
leon holmes

I live about 45 minutes east of charlotte, 2 1/2 hours from the blueridge parkway. I just sold my other 2 bikes last week and I'm already have withdrawls. I'm going to get this bike into the building and get started on it. I ordered a few things this morning, 4 carb rebuilds, reg/rec replacement, green coils and wires from Z1.

sound like progress,can't wait to see the results.

I got the bike setup in the shop and replaced the swing arm with the aftermarket one that I have, I will have to add an 1/2 inch offset front sproket to the list. Looks like I'm going to have to cut off the stock brake lever mount but I was going to have to replace it anyways for the new rear sets. I needed to get it fitted up before I removed the engine to be sure everything was going to line up before I painted down the frame. I also need to make a brake mount on the swingarm instead of the axle. Pictures are abit fuzzy, I'll have to take the camera out there instead of using the phone.


www.cruspeed.com/images/kz1.jpg
www.cruspeed.com/images/kz2.jpg
www.cruspeed.com/images/kz3.jpg
www.cruspeed.com/images/kz4.jpg

Your making your carbon fiber fenders?
eeeeeeeeeewwwwwwwwww... please share this process, images, tutorial....

Is it me or is that rear rim off center?

Definitely following this project...

OMR

i see u are off to a good start.
is that a 6" or 5.5" rim?

Rim is off center, I think I can turn 1/4 off the left spacer and 1/4 off the sprocket mount on a lathe and that should true it up enough or close enough to me. I also think I'm going to have to make an idle gear midway up the swingarm. I don't like the idea of keeping the chain so tight that it adds alot of pressure onto the final drive bearings. I think it's a 6 inch rim, gotta order some tires for it so I can really see what I need to do.

Carbonfiber is easy to work with, just like fiberglass but add a vacuum pump and clear epoxy instead of polyester. After taking a good look at the plastics on my bike it seems easy to do, no complex curves or hard mounts. I need to get a rear fender and some side plastics to play with before I can do much more with carbonfiber.

Been waiting on the offset sprocket to come in and the weather has been bad for the past week so that slowed me down alittle bit. I got the sprocket in last thursday and started stripping the paint off the old rims to get tires on them. It was a 1/2" offset with a 530 chain and it has about 3/8" clearance from the frame which is plenty. Once I did that I mounted the rear tire and did alittle lathe work and now it's good to go. I'm waiting on my block and pistons to come in but I'm going to go ahead and pull the engine and paint the frame and the few engine covers that will come off. Picked up some materials to make a mold for my windshield/fenders and side covers also, will start that soon. I will have to work on the paint and molds during the day while it's over 70 degrees here. Here's a few shot of the rear of the bike, the progress will pick up now that I know the rim/arm combo will work with the bike.



I can't figure out how to upload more than one image so here's some links-

www.cruspeed.com/images/offsetsprocket.jpg
www.cruspeed.com/images/rimandarm.jpg

Wow, that is 1 long arm. she's going to look nice. Did u go with an o-ring chain?
Keep us posted.

There you go! What are you doing for a tail section..stock length, extended?

Later, Doug

I got the frame stripped down to nothing but pipe, welds and paint. Will start the frame work within a few days seeing I just went from 12 rotation shifts to 8 hours straight shifts and have time everyday to mess with it. I split the case and I guess I got the KZ1000 Special Mechanics Edition because there was a 10mm socket in the case when I pulled off the bottom. Got the bottom half cleaned up and old paint stripped, got to wipe it down with acetone and spray some engine enamel on it. Monoshock and turning a new triple tree collar will be next on the frame.