Author Topic: 1977 Kawasaki KZ1000 LTD (Read 6183 times)

Kelly E · « **Reply #50 on:** November 06, 2022, 07:44:21 AM »

A Craigslist rebuild is knocking off the big chunks of grime and a quick spray paint job.

Mark1976 · « **Reply #51 on:** November 06, 2022, 03:07:42 PM »

Its Its always nice to have a clean, freshly painted base from which to move forward.

Kelly E · « **Reply #52 on:** November 11, 2022, 08:37:47 AM »

Yesterday we installed the rest of the motor mount bolts. The last parts to rebuild the rear brake master cylinder so we got it put together. I managed to get the original tach drive seal out after a small battle. The rubber was so hard it came out in chunks and then I pried out the steel shell. After that we started to clean up the wiring harness.

Kelly E · « **Reply #53 on:** December 08, 2022, 10:50:45 AM »

I'm still picking away at wiring harness repairs, waiting on a new fuse box. Yesterday we installed the battery box and electrical panel along with the rear brake master cylinder and pedal.
The new gauge mounting bracket came too but I'm still working on smoothing the upper triple tree and fork lowers so we can assemble the front end.
We also fitted the new seat for the final time. It latches smoothly and opens easily with the key.

Mark1976 · « **Reply #54 on:** December 08, 2022, 01:55:41 PM »

Looks outstanding, one thing at a time. Gotta love it when a plan comes together.

BenelliSEI · « **Reply #55 on:** December 08, 2022, 02:26:17 PM »

Amazed how far apart that bike came. Glad it doesn’t just happen to me!

Kelly E · « **Reply #56 on:** December 12, 2022, 08:11:52 PM »

Today I finished up moving the front turn signals from clamping to the handlebars to using them to attach the headlight bucket to the mounting bracket. Yesterday we installed the the new races and the steering stem figured out most of the turn signal move.
Once I get the fork lowers finished up we can assemble and install the front end. Then we order the brake lines and finish up the brakes.

grcamna2 · « **Reply #57 on:** December 12, 2022, 08:53:38 PM »

Kelly,when you had the turn sig. mounts in the lathe,were you turning-down the hex-shaped parts to make them round? Then you were able to push that turned-down shank all the way into the headlight bucket on both sides ?

Kelly E · « **Reply #58 on:** December 13, 2022, 08:42:24 AM »

Quote from: grcamna2 on December 12, 2022, 08:53:38 PM

Kelly,when you had the turn sig. mounts in the lathe,were you turning-down the hex-shaped parts to make them round? Then you were able to push that turned-down shank all the way into the headlight bucket on both sides ?

Yep, I turned the diamond shaped part down to 15mm and drilled out the holes in the mounting bracket to 15mm.

seanbarney41 · « **Reply #59 on:** December 15, 2022, 01:44:05 AM »

You could have done that with the right combination of oem parts, too. Your way is cheaper if you don' have access to lots of non-LTD Kawasaki parts

Kelly E · « **Reply #60 on:** December 15, 2022, 11:57:16 AM »

Quote from: seanbarney41 on December 15, 2022, 01:44:05 AM

You could have done that with the right combination of oem parts, too. Your way is cheaper if you don' have access to lots of non-LTD Kawasaki parts

With lower bars there's no room to mount them on the handlebars. I like it without the slip-on headlight mounting ears. I'm not trying to make it into a KZ 1000A. I will be getting a new pre-painted body set, the LTD gas tank is only 3.6 gallons and the standard tank is 4.8 gallons. I'll box up the original body set and put it away for safe keeping.

seanbarney41 · « **Reply #61 on:** December 15, 2022, 02:11:29 PM »

yeah I don't care for those handlebar mounted signals either. I have Z1/900 tank on my LTD...I think.

Kelly E · « **Reply #62 on:** December 18, 2022, 02:17:06 PM »

Today Paul and Ian came over and we assembled the fork tubes and mounted the front end. We were able to measure for the new shorter upper front brake line.

Kelly E · « **Reply #63 on:** December 28, 2022, 03:12:45 PM »

Today I finished up installing the new Mikuni RS34 radial flat slide carbs and the carb support rod. Now I have to make up the bowl vent lines and hook up the throttle cables. We're waiting on a new bigger set of carb intake boot clamps.
We also have the new brake lines ordered, it's starting to be close to done. Waiting for good test ride weather is going to suck.

seanbarney41 · « **Reply #64 on:** December 28, 2022, 03:25:56 PM »

Yeah! Lookin so good

grcamna2 · « **Reply #65 on:** December 28, 2022, 03:31:59 PM »

That Clean Machine is coming along Great Kelly

Mark1976 · « **Reply #66 on:** December 28, 2022, 08:31:10 PM »

Seriously good looking rack, but I've always had a thing for great racks....

Stev-o · « **Reply #67 on:** December 29, 2022, 07:22:38 AM »

Quote from: Mark1976 on December 28, 2022, 08:31:10 PM

Seriously good looking rack, but I've always had a thing for great racks....

+1 Haha...me too!

Kelly E · « **Reply #68 on:** December 29, 2022, 06:24:22 PM »

Today we put the gauges back together with a replacement wiring harness and gauge mount. I had to trim the 4 idiot light bulb sockets so they fit properly in the gauge mount. I also have the wiring sorted out and tomorrow I'll get the rest of it plugged in and routed.
There's still a bunch of stuff to do before trying to start it. I sure hope we get some warmer days at just the right time for some test rides.

Kelly E · « **Reply #69 on:** December 31, 2022, 07:56:06 PM »

Today I just about finished up the wiring harness including remounting the Dyna III ignition box. I'm waiting for some parts to finish it up the front turn signal grounds.

RAFster122s · « **Reply #70 on:** December 31, 2022, 09:00:26 PM »

Kelly it is looking good, hope you had a good Christmas and Happy New Years!
David

Mark1976 · « **Reply #71 on:** January 01, 2023, 07:33:02 AM »

Really great progress, looking forward to that intial start up and ride.

Kelly E · « **Reply #72 on:** January 05, 2023, 01:17:06 PM »

We received the new brake lines so we installed and bled them. After that we finished up a bunch of stuff and I got the fuel lines made. One of the fuel lines had to make a 180° turn right out of the petcock. I used the armour springs from the old brake lines to run the fuel lines through, it prevents the line from folding on the tight turn. I might have to trim the petcock handle because it hits the top of the #1 carb.

grcamna2 · « **Reply #73 on:** January 05, 2023, 03:27:42 PM »

That's looking good Kelly.

BenelliSEI · « **Reply #74 on:** January 06, 2023, 01:25:49 PM »

Kelly.... That beast is looking good!

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Author Topic: 1977 Kawasaki KZ1000 LTD (Read 6183 times)