KZ900 - updated suspension

Bama704

Been Around the Block
I am taking my '76 KZ900 and doing the swap to a 2003-2005 kawasaki 636 (zx6r) front end, I already have my KZ stem pressed into the 636 triple and it fits like a glove. I need to make the decision on using the clip-ons, or running some risers, would possibly need a new top triple to do this though. For the rear I have a gs100e swingarm that I will be doing sometime as well. Right now the fender for the 636 looks like absolute crap IMO and doesn't fit the look I want to get. I want something small that follows the tire and is affixed to the brake brackets using minimal metal, is this something I would have to more than likely make my self, or does anybody know of a place where I can buy this for my setup? It would look similar to the fender on my triumph.
I don't have the capability to form any sheet metal which is why I'm asking if I can buy it.
 

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doc_rot

Oh the usual... I bowl, I drive around...
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Cool, bike. Just a heads up but the 636 forks are pretty short in comparison to stock. These ol KZs are wide as hell and they need all the ground clearance they can get. Its possible to lengthen the forks internally.

You can run high or low rise adjustable clip-ons. I run the low rise clip on from Tarrozi https://www.fastfromthepast.com/clip-ons/high-rise?p=1

You can buy a cheap fender blank and work out the mounts yourself. something like this. https://www.ebay.com/itm/Motorcycle...601855?hash=item3654f5633f:g:kNUAAOSwafddjc9H
 
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Bama704

Been Around the Block
Thanks Doc. Appreciate the links that's what I'm looking for.
I was looking for zx9 forks but these fell into my lap, if I need to switch at some point after riding I could always look for the longer zx9 forks, or search for options on lengthening them internally. I was hoping that the 636 front end wouldn't be too much shorter since I already had my top triple dropped down about 2 3/4 inches in the tubes to begin with.

I'm sure you hear this frequently, but the detail you put into your 1000 is bonkers, truly a beautiful bike and thanks for taking the time to document along the way.
 

doc_rot

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thanks for the kind words

heres a link to lengthening forks for the future if you find you need to do that. its for a zx-7 but it should apply.
 

Bevelheadmhr

Coast to Coast
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An alternative would be to fit a stepped top yoke, the one in the pic is on a Z650 using ZXR6 forks..

z650 015.JPG
 

doc_rot

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thats hot. Tad bit more expesive but hten you could correct the offset to be better at the same time.
 

Bama704

Been Around the Block
Yup, that is pretty damn good looking right there. Got the second brake rotor and caliper installed yesterday. I may have to look into getting that top triple (in due time), looks like there are plenty of companies out there who make these.
 

Bevelheadmhr

Coast to Coast
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The top yoke in the pic was made by a mate of mine, in his home workshop. Not sure how much it cost, but it wouldn't have been silly money. That said they are never going to be cheap, as you have to start with a thick block of alloy and then a lot of machining labour to get to the final shape.

Here are some pics of it being made..
006.JPG
z650 029.JPG
002.JPG
 

Bama704

Been Around the Block
Have gone ahead and fitted a GS1100e swingarm with a 88-90 ZX10 rear wheel as well. The problem I'm dealing with now is trying to make sure my hub is actually from a zx10. The stud size should be 10x24 (when looking at the kawasaki part online), but when I measure with a caliper I'm looking at 11.8mm. The rear sprocket it came with was for a 630 chain and I'm going to a 530, and will also need to have a custom sprocket made in order to get the correct number of rear teeth to keep with the gearing I want.
 

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Bama704

Been Around the Block
My work around is I am sending my old sprocket off to Sprocket Specialists to make me a new one and to make sure the new sprocket will mate up with the hub. Once that is finished I need to install the rear caliper and make sure to get the wheel centered.
 

Bama704

Been Around the Block
I have the GS1100E swingarm mounted up and after getting the wheel in it looks to be centered and the sprockets align from what I can tell, but when I test fit the chain it is rubbing on the tire. If I were to do an offset front sprocket that is just giving me clearance to align the sprocket, which is already aligned so it would not help with my rear wheel clearance, right? Do I need to find an offset rear sprocket, or shim the sprocket?
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Bama704

Been Around the Block
A few other things I have done is I cut off the key location on the upper triple tree and drilled/tapped holes on the underside for my gauge mount. Hooked up motogadget M-lock instead of moving the key location, which is pretty sweet. It is behind one of the side covers. Got the rear caliper rebuilt and sorted out, now just trying to work a location to mount my master cylinder. I was going to use the 2 bolts for the engine case but it will interfere with removing my battery. Also got the Tarozzi rearsets put on and they look great.
 

doc_rot

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I have the GS1100E swingarm mounted up and after getting the wheel in it looks to be centered and the sprockets align from what I can tell, but when I test fit the chain it is rubbing on the tire. If I were to do an offset front sprocket that is just giving me clearance to align the sprocket, which is already aligned so it would not help with my rear wheel clearance, right? Do I need to find an offset rear sprocket, or shim the sprocket?
I would guess your wheel is not centered correctly or not straight in the swing-arm because the chain should clear the tire if its the stock hub and stock tire size. however you did mention there was some confusion with the studs on the hub of your wheel. Is it possible you have one from a different bike?
 

Bama704

Been Around the Block
The wheel is from a 88-90 zx10. Is it possible the hub is not, yes. I was looking last night and the hub does not sit flush in the wheel, I can see less than an 1/8" through to the cushion drive. I did not notice this before. Will have to do some investigating.
 

Bama704

Been Around the Block
Found the right hub on ebay for $20, score, should get it by by Friday and will know more then. Will have to order another rear sprocket :rolleyes:
 

Bama704

Been Around the Block
I would guess your wheel is not centered correctly or not straight in the swing-arm because the chain should clear the tire if its the stock hub and stock tire size. however you did mention there was some confusion with the studs on the hub of your wheel. Is it possible you have one from a different bike?
Doc you were correct. The new hub is the correct one, huge oversight on my part. The chain for sure clears the tire after a quick mock up, now I will just have to measure the correct offset once I get the correct rear sprocket, again. The black hub was the hold one.
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