My 1990 KZP build

Next is chain, sprockets, tires and clean, clean, clean. Used Marvel Mystery oil to get most of the stuff off. I like the results.

OK, at this point I had a running motorcycle, I was able to take it for a 150 mile ride with a few friends and it performed very well. As I was coming back home bike started to run with miss and no power. After a couple of seconds I realized that I needed to go to reserve. Flipped the toggle and straightened right up.

So, I never really liked the foot rests as they make the bike look big, wide and that heel toe shifter would never do for a quick shift. I also worried about how far I could lean in the turns so they had to go. I looked at a lot of pictures and decided that I could drill, tap holes in the existing gussett and install late 70s components. Got the peg assemblies, shifter, brake peddle on ebay. Had to get the correct transition piece but was able to source it out. They are pretty much the same. Anyway a couple of pics of the process.

So, now my world was complete! No more floorboards, Fast shift. Better feeling in turns. Life couldn't be better. So I took it out to show my son. Got there and when I went to restart it popped and was running on 3. Number 2 was not firing. So I limped it home and decided to tackle a couple of more maintenance things. Oh, and try to find out what's wrong.

So, now my world was complete! No more floorboards, Fast shift. Better feeling in turns. Life couldn't be better. So I took it out to show my son. Got there and when I went to restart it popped and was running on 3. Number 2 was not firing. So I limped it home and decided to tackle a couple of more maintenance things. Oh, and try to find out what's wrong.

So, I did some checks of the ignition and got some readings on the ignitor that were suspect. Well, that was enough of an excuse for me to buy the Dyna S and install it. I figured like many that a 30 year old system can only cause trouble at the most unexpected time. It was something I had wanted to do but thought about the cost and talked myself out of it. Well now it is installed! I figured while I was in there I should check the valve clearances. I had not done this yet but knew the bike had 72k on it. Assuming the cops performed proper maintenance that means they weren't looked at since 50k or so. Any, the PO said he didn't inspect them. Well, I did find 3 that I couldn't get a feeler gage in and a couple of other tight ones. So off to Z1 and wait for parts.

bike is gonna run sweet after the valve adjustment. Nobody likes doing it but it really does make a difference.

bike is gonna run sweet after the valve adjustment. Nobody likes doing it but it really does make a difference

Indeed I have taken it out for a short run and it seems to run great!
I'm taking it out tomorrow for a longer stint to make sure it is all there. It started and sounded much better with the valves adjusted and the Dyna S. It ran so strong that at 70 mph I rolled on the throttle and at around 4500 rpm it broke the clutch loose in 5th gear. Looks like I'll need to look into that as well. No slippage in other gears but I figure the engine is putting out some torque.

So more catch up..... So, while I was waiting for the Dyna S and the shims I needed I continued cleaning. Came out to the garage one day and noticed fork oil on the floor. So.....I just had to disassemble them and replace the fork seals and replace the fork oil. Needless to say the fluid that came out didn't look like oil, more like sludge. Well, had to wait for the seals as well. I guess the most anxiety I had was leaving the front tire off on the center stand and jack to support it. I wouldn't recommend how I did it as it was tippy enough to make me nervous indeed. Got the forks done and re-installed along with the front wheel and still waited for parts. Finally got them and installed the new shims and the Dyna S. I lowered the back down by adjusting the springs on the rear shocks so I lowered the forks in the triple trees 1/2" to compensate. Seems OK.

While I was at it I replaced the 4ea seals and the cover gasket on the sprocket side as I had a leak that was just begging to be fixed.

So, this is how it sits now and I'm sure I have left something out but I did add bar end mirrors. Now I have to decide whether to change out the rear fender and or put the KZ tail section on as I do like that look and whether to keep the stock exhaust or not.(PO put new exhaust on the bike just before the original wreck). I think I'll just ride it until the weather gets bad before I make any more decisions. Probably another week or so here in the northwest.

Now that I am caught up I will try to document any further changes as they are completed.
P.S. My stepson says my bar ends look gay. :laugh: