Testarossa's 78 KZ1000 Fighter Build

  • mark1122
  • Offline
  • User
  • Keep twisting it
More
03 Jan 2010 14:31 #341704 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
Dont skimp on the frame gussets. there will be no point in firming up the front and rear end if u dont firm up the middle(frame) . B)
Good luck.
Mark

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

Please Log in or Create an account to join the conversation.

  • mark1122
  • Offline
  • User
  • Keep twisting it
More
03 Jan 2010 15:08 #341710 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

Monday update here. Also, looks like the alternator rotor spun on the crankshaft. The end of the crank was slightly galled and that bugger was a bear to remove. I need to get some pics of the hidden bolts to remove before you try to split the cases. I'll try to post these tomorrow.

how are u going to resolve this?
this is common to the z1 cranks. the kz crank has a big ass bolt on the rotor (95ft.lbs.)the z1 is small(17ft.lbs.) if i recall correctly. u will want to have the crank welded to prevent the pins from slipping. they are only press fit together and with added cc's and compresion they recommend welding.
I have 1 in great shape, all welded and redy to go . PM me if interested.

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

Please Log in or Create an account to join the conversation.

  • testarossa
  • Topic Author
  • Offline
  • User
  • Attack life, it's only trying to kill you.
More
06 Jan 2010 08:12 #342001 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Thanks for the pointers Mark1122. I must say that your bike has served as inspiration as well as OMR's. I finally found OMR's build thread and I will consider my options for the stem.

As far as the crank is concerned the galled section is just the tapered end where the rotor mounts. I just figured that I could polish and re-assemble. Will this not work? My plan is to use this motor with stock pistons so I want to slap it back together as cheaply as possible. I will be spending most of my budget on frame mods and paint. Once I get it running I'll start working on the hot-rod motor. Possibly next year on that one, so hang on to that crank for me.

Finally, I plan on gusseting the frame myself. This actually raises a point. What size tubing are we using for frame braces? Is everyone using 4130? What wall thickness are the standard frame tubes?

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

Please Log in or Create an account to join the conversation.

  • mark1122
  • Offline
  • User
  • Keep twisting it
More
06 Jan 2010 19:06 #342050 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
I could not over come the rotor slipping until i replaced it. i tried lapping it on with valve grind compound, and red locktite. it keeps coming loose and stranding me.each time it would shear the woodriff key, and score the crank a little bit more.
so i gave in and replaced it.
u could try a harder bolt. i actual got a spare crank end to test a harder bolt in. i thought i could torque it until lt it stripped, then i would know how many ft lbs torque it could handle before failure. but i never bothered to test it. i just got another crank. i had guys tell me they used a harder bolt and a impact gun, but that was too unscientific for me. lol.
On the gussets, moly would be lighter, but not necessary. u dont need to go as thick as stock wall thickness. i have some info if u would like it just PM me with your e mail addy.

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

Please Log in or Create an account to join the conversation.

  • testarossa
  • Topic Author
  • Offline
  • User
  • Attack life, it's only trying to kill you.
More
06 Jan 2010 19:19 #342052 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Funny, mine doesn't have a woodriff key.
You have PM.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

Please Log in or Create an account to join the conversation.

  • mark1122
  • Offline
  • User
  • Keep twisting it
More
07 Jan 2010 14:01 #342121 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
testarossa wrote:

Funny, mine doesn't have a woodriff key.
You have PM.

Sorry, I’m bad. u have a 78. OK then, u should have a large bolt in the rotor end. check and see if it is about 10mm , or a smaller 8mm. I could be wrong on the exact size, but if u have the small 1 it's not great. Most 78/80 kz's have the big 1, but not all.
But the same applies to what I said above. u must reduce the scoring on both surfaces to have a chance. But if u have the big bolt, u have a better chance of success.
I will try to round up some info for u on the week end.B)
Have fun with your build. And thanks for the great write up on dismantaling the shocks. i will keep a for copy myself. B)

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

Please Log in or Create an account to join the conversation.

  • testarossa
  • Topic Author
  • Offline
  • User
  • Attack life, it's only trying to kill you.
More
24 Jan 2010 19:49 #344419 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
I know its been a while since my last post, but I have been a busy boy. First I must publicly thank Mark for all of the info that he has sent me about frame bracing. The man is a saint. He has saved me many hours of research. I hope that I can return the favor in the future.

Now, on to the progress. I have taken Mark's suggestion and pressed the KZ1000 steering stem into the lower triple clamp from the GSXR. I had to turn a spacer on the lathe at work, and I couldn't wait to press it in, so no pictures. Now thanks to a new tapered bearing kit courtesy of the fine folks at Z1 I now have the front end on the bike. Unfortunatly, when I cleaned all of the accumulated dirt from the forks, I discovered that the right lower fork leg is TOAST. Loads of tiny chips in the chrome. That thing is a cheese grater. Not putting my new fork seals on that one. Found a whole front end on Ebay, which the seller assures me is in perfect condition. So the cheese grater will suffice for mock-up purposes and spare parts. I also decided to weld up some proper front end tools which I will will use when I rebuild the new front fork.

DIY fork spring compressor.

I also turned a pair of spacers to fit the GSXR swingarm to the KZ pivot bolt. Basically, just drilled and bored the inside diameter to fit closely on the the pivot bolt (0.630" IIRC.) The outside diameter was turned to match the GSXR pivot, and the flanges on either side were 0.050" thick to tightly locate the swingarm in the frame. The swingarm was 0.100" narrower than the frame, and believe me that this thing is tight.


Now I need to weld in mounting tabs for the mono-shock linkage and the upper shock mount. At that point I will have a rolling chassis. WOO-HOO, party, milestone! Then I can start fabricating frame gussets.

Starting to look like a motorcycle again.


With the current suspension, you could say that the rear end feels a little "wooden."

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

Please Log in or Create an account to join the conversation.

  • mark1122
  • Offline
  • User
  • Keep twisting it
More
26 Jan 2010 19:42 #344830 by mark1122
Replied by mark1122 on topic Testarossa's 78 KZ1000 Fighter Build
Thanks for the kudo's. I'm glad i could help.i may need a good machinist some day.lol. Just kidding.
What did u get for the new front end?
I am going to modify my zx9 top tree. i want to lower it to raise the front end an inch. This will help me satisfy the rear ride height , which is too high at the moment.

76 KZ, frame gusset work,1200CC.Ported by Larry Cavanaugh, 1.5mm.over intakes, Carron Pipe, ZRX12 rear end, and seat,96zx9 front end.
01 CBR600F4i Track bike.
Cobourg, Ont. Can.

~ ~ ~_@
~ ~ _- \,
~ (k) / (z)

Please Log in or Create an account to join the conversation.

More
26 Jan 2010 20:41 #344844 by jeffasaki
Replied by jeffasaki on topic Testarossa's 78 KZ1000 Fighter Build
Now to give some pointers,When removing old steel to aluminuin bolts never fear a bit of heat from a propane torch also when dealing with old phillups drive take a flat face punch and give it a good thwap then get a good snapon phillups drive and use a 10mm or a 3/8 to hold on to the old bolt.give it a good tap into place.If you have the correct tool (a screwdriver with a oversize phillups drive drive)it should come out.If it doesnt dont try to crank it out.Give it a little heat let it soak in then try again.If it dont come out the first time just keep repeating this process itll work itself out eventually. All this shit is rare so please take care

78 Z1R
78 KZ1000
76 KH500 gone
71 HS1B 90
81 GS 1100 gone
80 PE400
02 KLR


Ontario Canada

Please Log in or Create an account to join the conversation.

  • testarossa
  • Topic Author
  • Offline
  • User
  • Attack life, it's only trying to kill you.
More
27 Jan 2010 06:58 #344882 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Mark-I got another 95 GSXR front end off of ebay for $150, and met a really knowledgable GSXR guy to boot.

Jeff-That's a good pointer about the propane torch. I was just about to break out the ole' hot wrench, but the impact screwdriver technique worked on all my case screws. Unfortunatly, it looks like a whole new set of screws are in order. Mine are a little too knackered to go back on the bike.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

Please Log in or Create an account to join the conversation.

  • Kawickrice
  • Offline
  • User
  • After Monday & Tuesday, even the calendar says WTF
More
27 Jan 2010 07:09 - 27 Jan 2010 07:14 #344883 by Kawickrice
Replied by Kawickrice on topic Testarossa's 78 KZ1000 Fighter Build
Z1E sells a metric stainless allen bolt set for your motor. I bought three sets from them in the past few years. One for my 900, one for my 650, and one for my RD350. Very reasonable on the prices too.




www.z1enterprises.com/detail.aspx?ID=2674

73 Kawasaki Z1
07 HD CVO Ultra Classic
82 Suzuki GS 1100
74 Yamaha RD 350 (My two stroke toy)
77 Kawasaki KZ 650B-1 (My putt around bike)
80 Indian Moped (My American Iron)
1
Long Gone
75 Suzuki GT550
74 GT 380
79 RD 400 Daytona Special
72 Honda CL 175
74 Honda QA 50
Tampa FL
Last edit: 27 Jan 2010 07:14 by Kawickrice.

Please Log in or Create an account to join the conversation.

  • testarossa
  • Topic Author
  • Offline
  • User
  • Attack life, it's only trying to kill you.
More
27 Jan 2010 07:14 #344884 by testarossa
Replied by testarossa on topic Testarossa's 78 KZ1000 Fighter Build
Yeah, I def. have my eye on those allen bolts from Z1E. I like allen heads better than phillips heads any day.

1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN

Please Log in or Create an account to join the conversation.

Powered by Kunena Forum