1990 KZ1000 police cafe build

[Cuff]

Nice build my friend. Great bike but I'm kind of bias. ;D Good to see your take on the old KZP's.

 

[roman_dog]

Nice build my friend. Great bike but I'm kind of bias. ;D Good to see your take on the old KZP's.

Thanks Cuff. Question: Is that your KZP and can you tell me about those mufflers you're running on it? They look kind of cool, and in case mine turns out to be a bust I'll need another option.

 

[1fasgsxr]

So I think I found the problem with my xmsn jumping out of gear, but I'll run it past the masses. I'm certainly no expert. Here is the shift drum detent I pulled, and I assume that the wear on the roller in giving the shift drum just enough room to pop into neutral.

Here is the roller as it should be, I think.

Here is how bad it is worn. Would this be enough to cause my problem?

Don't know if your back together with your engine yet as I just stumbled across your build and have only made it this far in....but in my experience of these bikes the shifting problem was usually a bent shifting fork...not 100% on yours as it is a newer model than I am familiar with...

 

[1fasgsxr]

HAHA...guess I should have read on ahead....bike looks great man !!

 

[Cuff]

Thanks Cuff. Question: Is that your KZP and can you tell me about those mufflers you're running on it? They look kind of cool, and in case mine turns out to be a bust I'll need another option.

They are just 9" glass packs from Summit Racing. I've since gone to the 12" with baffles to keep the neighbors happy.

 

[roman_dog]

Don't know if your back together with your engine yet as I just stumbled across your build and have only made it this far in....but in my experience of these bikes the shifting problem was usually a bent shifting fork...not 100% on yours as it is a newer model than I am familiar with...

Yup, all back together now. I haven't gotten it on the road yet, so I'm not 100% sure that the problem is fixed. I'm reasonably confident though, as everything else checked out. Shift forks were spot on, all the slider rods were straight, ect. The only possibly concern I have is one channel on the shift drum has a small chip in it. The book said this might be a cause to the xmsn jumping into neutral, but the chip was so small I wasn't willing to bet $250 on a new one. Oh well, time will tell.

 

[roman_dog]

This has nothing to do with my build, but who doesn't love Corsairs?

 

[MotorbikeBruno]

This has nothing to do with my build, but who doesn't love Corsairs?

Amen!

 

[haplo_84]

One of the most beautiful WWII planes ever made.

 

[roman_dog]

OK, so here are some updates. I was able to knock a few more things off the completion list. I've got the exhaust mounted, after letting the paint cure for a solid week. I got the front brake line, but I might see how much it is to have one properly made. No sense half-assing on such an important part. Here is the exhaust:

 

[roman_dog]

Another thing I got done is the top fairing. I figured out the question that's been bugging me: how the heck am I going to mount it securely? Here is the answer:

This seagull-esque looking bracket is what will hold the aft part of the fairing:

A pic of the inside how it sits:

How it mounts to the bike. I simply attached it to the intrument panel.

Here you can just see the bracket above the gauges. I'll run a couple screws through it tomorrow.

 

[Das1slickninja]

Lookin good man! Can't wait to see it all come together!

 

[roman_dog]

Here we go, update. I finally got my push buttons in the mail so this means I can move forward with the electrical system. After a solid day's work, I managed to figure it all out again, haha. I also got some rubber trim for the fairing edges.

Also got a new signal blinker.

Tell me, how does a "bare bones" wiring harness turn into this?

Cleaned it up a little.

 

[roman_dog]

Once I got the electrical all done, I tried firing her up. Worked like a champ! She still idles fast, about 3500, but I haven't synched the carbs up yet, hopefully that can slow them down. So I answered two more questions that have been burning in my mind. One, should I mount the chain guard? And two, where the heck am I going to mount the licence plate? I managed to kill two birds with one stone here and am just going to bolt a bracket right onto the chain guard. Problem solved, once I make said blaket I'll post up a pic.

hmmm, it doesn't look great...

Here's where It will be:

 

[roman_dog]

OK, I spoke too soon when I said that the electrical was all done. Two things remain: the charging system isn't charging, and the rear turn signals. Hopefully someone can confirm my suspicions before I go spending more money.

Here is my setup, all the turn signals are LEDs and the flasher unit is thermal operated. When I substitute an incandescent turn signal for the back (in parallel with the LED front) it flashes and works properly. When I wire the LED rear with the LED front, that side will come on and stay on. No rapid flashing or anything like that. I'm trying to figure if I should install a load equalizer.

Would a load equalizer solve this problem? Would I need one for each set of turn signals, or just one for the entire circuit?

 

[roman_dog]

OK, so I made the license plate bracket. Nothing special, just a piece of aluminum I bent to match the chain guard. Installed the chain, aligned everything up nice and neat. I've never messed with a tensioner before, so I simply set the chain at the factory recommended slack, then threw the wheel in there. If anyone thinks there is a better way to do this, please learn me up before I ruin something, haha. Tomorrow I'll dig into the charging system and get that working. I'm also throwing in some teaser photos of my girl with her clothes on

I added some rubber trim to the top fairing. The same thing will be done to the back fender.

No headlight

 

[roman_dog]

Got the charging system working, it was just another ground wire. This one however only took me about a minute to identify. Learned my lesson with the damn ignition module!

 

[andycafe]

Nicely done r-d, that exhaust looks mad ;D great job ........ andy

 

[roman_dog]

Nicely done r-d, that exhaust looks mad ;D great job ........ andy

Thanks Andy. Its obnoxiously loud too. ;D

 

[roman_dog]

So just messing around with detail stuff today. I put on my mirrors and instantly didn't like them. I have right now the bar end type mirrors, which look good by themselves, but they add about 7" to the width of the bike, which I don't like. I started looking for some stem mirrors, but no luck finding ones I liked. Anybody know where to get some black 3" round short stem mirrors? I've found plenty of 4" ones, or chrome ones, but what I want proves elusive.

Here are the mirrors, kinda funny looking

This is what I'm looking for, but with 3" mirrors. Anybody?