'76 KZ900 (ZRX1200R) Build

So on Saturday while waiting for a potential buyer for our RV, I got to spend some hours working on the KZ. First off, I fitted the cover and belt drive for mock up.

Then fitted a little bling....

Then rough cut the center out oof my Harley Cush Drive.

Then using my brother's new lathe, turned it and trued it in prep for my collar and sprocket.

Then turned my attention to putting on and fitting all the D&G Chassis motor mount stuff. Started with the front mounts.

Then the rear chromemoly mount. Which eliminated the old mounts which had the battery box brace tabs. So I jigged the battery box in place and cut the brace down to a minimum and welded it into the new motor mount once in position. then cut down the old long bolt and rethreaded it.

Then decided I ddin't like how my current location for the rear brake master resivior got mounted, so I decided to move it to behind the side cover. Made a new bracket and welded the bracket to the battery box. Came out nice I think.

Finished up by adding my last brace to the exhuast hanger mount.

Then used my bro's lathe again to make some special bushings and my alternator stand off as can be seen on the RH side of the pic.

Well, that is all I got done, not much. It will be a couple of weeks before I can do more as I will be out of town on vacation. Hopefully my wheel will be back and I can get that fitted up!

Cory

Wow, that guy must have been really late! :lol:

Looking great!

Looking at your remote alternator, I was reminded that there are some shots of a cool setup like that in the documentary "Z1: The Movie".

I believe the bikes with this setup are all Egli built bikes. I can't find any pictures that exactly match what I remember seeing, but here are some examples of Egli remote alternators.









Maybe someone who actually remembers where they put their copy of the DVD can take some screen shots...

Cool pics! So far all the belt drives I have seen are one off's and most don't keep the electric starter operable. I wanted to keep the starter in tact. Did have to order a different belt as one was really too long and one was too short for where so want the alternator.

Cory

NakedFun wrote: I wanted to keep the starter intact.

I think I could live without the electric start, but I haven't actually tried. Those stupid batteries are always on the edge of dead anyway, so I frequently end up pop starting the bike.

I've been wondering if it would be possible to fit the alternator from a ZX11 or possibly the similar Suzuki Katana units down into the recess for the KZ1000 starter motor.

These alternators looks to be a bit larger in diameter than the starter, but might be close enough? They are smaller than an automotive unit anyway.

I think finding a way to drive them with gears would be the most difficult challenge of using them in place of the starter. My kick start is deleted as it would not work with my pegs from Les.

As far as alternator size, this is a permanent magnet alternator with built in regulator so it is a simple 2 wire hookup and self regulating 40 amps come out... Also has the option for a failure light with a third wire. Much cleaner, reliable charging system IMHO. I am building my own electrical system since I really enjoy designing and fabricating that stuff.

Cory

79MKII wrote: Wow, that guy must have been really late! :lol:

Looking great!

AHhaha! :lol:

Hey Naked are you putting a cover on it? It looks like the belt is right where your lower part of your leg will be. With the SC cover of my bike it's dangerous for the same reason, it was rubbing on my jeans even when I was trying to avoid it..

Kind of a guard.... Lol

Cory

Buchanan's sent my reworked wheel back... Getting closer....

Cory

sweet!


leon

Quickie Update... Almost finished the belt drive alternator. May machine an additional brace for the main pivot bolt and FINALLY got the right belt. Machined up a custom turnbuckle for setting tension.

No onto the wheels... Since I ended up trying a different hub, now I need to machine .385" off the hub to get the cushdrive into alignment and need a big lathe for that swing....ugh! May have to disassemble and the reassemble the rear wheel... what a PITA!

Cory

Cory,

Your project looks great! I like the innovation you're putting into it.

Now, I just need to hop back over to my 900 project since you've given me some inspriration. I've drug it out way too long...

Later, Doug