'83 KZ1000R2 - Cafe racer (take two)

I am creating a new thread for this build, as the last one was converted into more of an ethical thread than a build thread No hard feelings. But please let's keep it this time to discussing the build and not what bike is being used for this build. So here we go.

Firstly a little intro:

I really love Cafe Racers and I have always wanted to build my own. My first bike was a Suzuki GS400 Cafe racer that I did not build myself, but bought from a guy in Norway who builds Cafe racers based on GS400 together with this son:

Another pic


After I had been riding this bike for a while, I was interested in building my own Cafe racer and had been doing quite a lot of research. I wanted to build a bike that had a bigger engine with more power, like a 750cc or 1000cc. I had been looking at the Suzuki GS750, GS1000 and the Honda CB750s, also KZ750 and KZ1000. The market for classic bikes is not so big in Norway, as I guess it is in the US where most of you come from. Therefore it is not all that easy to actually find a bike for a build project, unless you import one from another country. After browsing through the "bike for sale"-adds in Norway for a while the one bike who caught my eye was the KZ1000R2 that I could get for a resonable price. I managed to get a fair price for the old GS400 and did not have to put all that much in upgrading to the KZ1000R2. So here we are.

The project is a '83 KZ1000R2 that has run for about 70.000km and had a shit load of different owners. Access to parts and workshops her in Norway are limited and therefore also pretty expensive. All the parts I get are bought on-line from webshops (Z1enterprise, Fast from the past, Dynoman.net etc.) or ebay.

My first sketches started out like this:

Based upon this sketch I did a qucik part conversion using the stock seat and added clip-ons, new headlight and an Acewell speedo. This was during the riding season, so I did not want to use much time on it, and just wanted to get the Cafe feel of it:


This is all I have time for writing right now. As some of you might know, I have done much more work on the bike today, and I will upadte this ASAP.

I'm not into those myself, however your first one there looked pretty good. Only thing you guys don't have much padding on them seats though(lol). Good luck with your build and give it your best.

The front fender does not look right on it anymore.

Try a shorter fender like one from an ltd

I am glad to see that you are moving ahead with this project! Share lots of photos and keep us updated.

It was perfect before you cafe-ed it.

Kapahulu wrote: It was perfect before you cafe-ed it.

Can't un-ring that bell.

Go Tommy!

peter1958 wrote: The front fender does not look right on it anymore.

I agree that the fender did not look right. I have shortened it a bit. This beeing the original fender:'

And this being after:

I have used the two cut-off parts and welded them together to make a hugger/fender for the rear swing arm:

Before I go on with more pics, here are my initial plans for this build:

- Tearing down engine compeletely and having it meda blasted and re-painted. I will do a combo of black and silver on the engine.
- Sandblasting the frame and having it powder coated (black semi-gloss)
- Painting tank, seat and fenders black with some white racing stripes
- Rebuilding engine with Wiseco big bore kit (72.0mm) to 1075ccm with new valves and guides
- Replacing front and rear drive train sprocket along with new 630 chain
- Changing the carbs from stock CV to Mikuni RS36 with K&N pod filters
- Change to Dyna S ignition with Dynca Coils (I am keeping the option of running the stock ignition)
- Changed fork stanchions (as they were shot) and springs to Hagon Progressive. Also putting on a fork brace.
- Changed rear suspension to progressive suspension, was thinking of Öhlins but I have to save up for that
- Installing hydraulic clutch system from Z1 Enterprises
- Replacing all bearings in stem and swing arm
- Replaced the stock Kerker baffle with 2" competition baffle
- Clip ons (that one was obvious?) and rear set installation
- Replacing front master cylinder and all brake lines with new and improved ones
- Fresh rubber on all wheels

Some non performance, but still cool addons:
- Acewell speedo/tacho
- Keyless ignition (RF-id based)
- LED blinkers

Wanted upgrade (stage 2):
- Brakes, I will need to see how they perform now after switching to new front master cylinder and brake lines.
- Front and rear assemblies of a ZRX (i hear that this is not to difficult to fit together)

RaceTech is making some nice shocks. They are worth a look too!

www.racetech.com/page/id/98

Tommyboah@gmail.com wrote: Before I go on with more pics, here are my initial plans for this build:

- Tearing down engine compeletely and having it meda blasted and re-painted. I will do a combo of black and silver on the engine.
- Sandblasting the frame and having it powder coated (black semi-gloss)
- Painting tank, seat and fenders black with some white racing stripes
- Rebuilding engine with Wiseco big bore kit (72.0mm) to 1075ccm with new valves and guides
- Replacing front and rear drive train sprocket along with new 630 chain
- Changing the carbs from stock CV to Mikuni RS36 with K&N pod filters
- Change to Dyna S ignition with Dynca Coils (I am keeping the option of running the stock ignition)
- Changed fork stanchions (as they were shot) and springs to Hagon Progressive. Also putting on a fork brace.
- Changed rear suspension to progressive suspension, was thinking of Öhlins but I have to save up for that
- Installing hydraulic clutch system from Z1 Enterprises
- Replacing all bearings in stem and swing arm
- Replaced the stock Kerker baffle with 2" competition baffle
- Clip ons (that one was obvious?) and rear set installation
- Replacing front master cylinder and all brake lines with new and improved ones
- Fresh rubber on all wheels

Some non performance, but still cool addons:
- Acewell speedo/tacho
- Keyless ignition (RF-id based)
- LED blinkers

Wanted upgrade (stage 2):
- Brakes, I will need to see how they perform now after switching to new front master cylinder and brake lines.
- Front and rear assemblies of a ZRX (i hear that this is not to difficult to fit together)

Very nice Tommy. Sounds like you will have a new bike once you are done. If you are replacing the chain and front and rears sprockets, I would look into converting to a 530 chain when you do it. Much lighter than the big 630 battle ship anchor chain. Definitely go with stainless steel braided brake lines. You can get them with a black or clear sheathing. Will be the single most important change you can make to your stock brakes, If you go to a new modern style caliper and M/C I would assume they would come with the SS lines. But even if you keep your stock components, it will drastically improve your brakes. Not saying it will do stoppies. But a big improvement.

- Changing the carbs from stock CV to Mikuni RS36 with K&N pod filters Just re read this again and those carbs are to big for this build