TOPIC:

the kz's seem to have only the bare minimum for venting. lots of guys report oil coming from the vent tube, especially with a bit of ware on the rings and bore. so i increased the vent hole sizes. some guys add a vent tube to the cam cover, or in place of a kickstart shaft.
i did the kickstart area first, but i got a $100 fine from the cops for altering the emissions system. so i tried to make it less obvious by altering the stock system to have a larger air capacity.

Thats a good idea. I could still enlarge mine. Do you remember how much larger you went? I just wondered what size would be sufficent. I also would like to run a low profile cover. How does everyone run theres? Do you just take out the plates with the rubber elbow runners on them? I know it also takes a shorter bolt. As far as the starter goes its just a starter for a 1979-1982 honda cb900F? Does it bolt right up and fit the starter gear? Thanks for all the help, Eric

Powerstroke_fan wrote: ...am ready to order a new REAR sprocket for my new build and i am wondering which will be the best size to go with? This bike will be street ridden. I dont want it reved out at 55 or 60. I will be getting a special sprocket made so i want to get the right size first time round. Currently iam running a 39 tooth on the rear. I thought about stepping up one tooth? I think iam running a 15 on the front but not sure.I will discuss front sizes later when i get to that point. Anyway iam taching about 4.5g at 55 if i remember correctly. Would like to get it down a bit yet still have some bottom end power also. so what does everyone think will be the best size?

Am thinking the stock rear sprocket is 33 teeth or maybe 35 teeth, with the stock counter-shaft sprocket being 15 teeth.
The currently fitted 39 teeth rear provides a lower than stock overall gearing that results in a higher rpm for any given road speed.
55 mph at 4,500 rpm seems more like a stock bike cruising in 4th gear instead of 5th gear.
Adding another tooth to the rear will further lower overall gearing for an even faster spinning engine at any given road speed.
Might want to consider returning to stock size rear sprocket.

Good Fortune!

most street guy’s go with 530 chain because it ends up being more economical in the end. if u want a street gearing and a track gearing it is cheaper to buy to stock sprockets for the rear than 2 custom 630's. not pushing u 1 way, just letting u know . maybe Less could cut the teeth off the stock 530, and weld a 630 to the side of it. This would offset the chain outwards they way u need, and alleviate the need to mill the hub??? Just thinking out loud.
have a look at page 6 of my build it will give u the size #"s i used for the vent. but if u want a low profile vent cover this is out the window, since it removes the vent from that location. in which case u will need to drill and add a vent elsewhere.

Pg6.
kzrider.com/forum/11-projects/103381-76-...e?limit=20&start=100

My Starter solution was to pick up a starter on EBay from a 1980 Honda CB900f and install it. Many F models use this starter. 750f 900f 1100f
It bolted right in, but it needed work
to clearance the sprocket cover to allow for the different position of the power lug. A bit of grinding, trial and error until I got it so it wouldn't short out against the sprocket cover.
I have since heard that u can just take the starter housing off and rotate it so the power wire bolt, is relocated to the proper position, just like the KZ. Then u don’t have to grind the cover ,its just plug and play. Of cause if u run a support plate like u should, this won’t be an issue.
The change from the .6Kw KZ stock starter to the .8Kw Honda starter made a HUGE difference.
U need to ask the seller to look on the side of the starter and make sure it says .8kwh on it. Some r .7 kwh.

Mark1122, your bike is awesome. So what all would go into venting thru the cam cover possibly thru the emmission ports? And i really thought about 530 conversion its just i got a almost new chain one season and its a 12,000# pound chain if i remember correctly. The bike will only be a street bike. I probably wont ever drag it at the strip. If so it will only be once. I just planned on ridding it on the street and country back roads. But it probably would be cheaper in the end tho. I just thought one sprocket and thats it. Iam still in the learning stage so all your advice is very helpful. I am still making small changes here and there. So any other advice is wanted i wanna only do this once. Thanks, Eric

"I ONLY what to do this once." i have said that a lot myself. lol

well, u r in the right place, there is a wealth of experiance to draw from here.
keep us up to date with your progress, and we will try to keep u to that statment above.
pics realy help. sometimes guys will spot things in the pic, that can give u a heads up.
do u have your own welder or mill?

ask leon and Less about the rear sprocket idea. i know Leon has made counter sprockets before.
have u tryed searching
www.sprocketspecialists.com/sprockets/products/suzuki for 1 ? it says on there web site that the 99 to 06 busa uses a 630?? last 1 on the page of that link. is that wrong??
why did u feel the need for the lock up clutch if u wont be drag racing?
dont for get to gusset that frame too.
oh, as for the vent. it doesnt matter so much where u vent, just vent. some guys just drill and tap a fitting into the top side of the cam cover. just dont put it where oil can fling into your vent. thats why i chose to mod the stock vent. it has the rubber tubes to redirect the oil back down in the motor.

can u post some pics of your tail lt? and how u installed it? it looks like a zx12, is that right?
i bought a zx12 lt but it seems to have to be mounted on a tilt to get it in there. or i would need to cut out some of the undertail glove box to recess the light way in under the tail.

sorry mark i must of not seen your last post. i can post some pictures of how i did it, if your still intrested. Anyway i have been really busy the last week, between getting a new truck and work and picking up my engine parts. Anyway later i will post pictures of everything.

Well, i know its been awhile since i updated my build thread. I have made alot of progress since my last post. My stupid web browsers wouldnt allow me to load pictures. Ended up going with google chrome and appears to work. So here is a few pictures of what i have did already.

Here is a few pictures of the pistons and jugs finished ready for install.


A side view to show how shiny it is and to show where the holes were epoxied to make it into a cheater block.


Picture of the top of the jug to show the massive holes in it.


Heres the 80mm mtc pistons. Arent they so purty


Another side view

The engine mostly put back together

A little more polishing

The frame after a quick paint.

And finally a pic of the swingarm after a nice paint job.

Have got the swingarm installed and the front steering stem bearing replaced, new wheel bearings installed. In the process of rebuild front forks as of now. I am working on getting the last spacers made for the rear wheel and it will be done. I still gotta get a few little things like a masterlink a few o rings and some other little stuff. but overall the build is getting alot closer to being finished.

What did you do to get the finish on your cylinder?