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-- A very special Z9 Kawasaki -- By Rick McDowell What do you do if you’ve got a VFR 400 Honda single sided swingarm lying around, and your mate just happens to have a 1970s Z900 Kawasaki rolling wreck ? For Alex and Kerry in Perth, Western Australia, the obvious answer was to combine the two items and create the absolute visual stunner you see here. The bike actually belongs to Kerry, although the two friends quickly realised that in addition to building a virtual gob-smacker, they could create a mobile business advertisement for their respective workshops, namely Roo Racing and K & D Chrome. Alex, the proprietor of Roo Racing, got the project under way by stripping the original Z900 back to a bare chassis. Although an excellent motorcycle engineer and manufacturer of high quality carbon fibre mufflers, Alex figured it’d be best to bring in another expert for the actual mating of Z900 chassis to NSR swingarm. Murray from Cycle Craft Engineering is more used to custom fabrication work with old British bikes, but the idea of joining a Honda single sided swingarm to a Kawasaki Z frame was a challenge he just couldn’t refuse. Murray began by sleeving the Honda swingarm so that it would accept the original Kawasaki through bolt and completed the job by manufacturing numerous distance pieces and bearing bushes to accommodate all the differences in design and measurement. Perhaps the biggest single task in mating the Honda Pro-Arm to the Z chassis though, was how to attach what is a mono shock swingarm to an old twin shock chassis. This was achieved by a custom made triangulated tubular steel upper shock assembly welded to the rear of the Kwaka’ frame and which supports the upper end of an RGV 250cc Suzuki shock absorber. The VFR 400 suspension linkage which came with the swingarm has been utilised too, and is attached to the frame by brackets which have been welded to an already existing lower frame member that runs across the rear of the Z 900 chassis. These brackets were then supplemented with additional box section, which was also applied to several adjoining original seams on the Kawasaki frame. The old Z tubes were significantly braced in
other areas too - such as around the head stem and spine as well as at the
front and rear of the engine cradle.
The
rear sub frame was ditched completely and all brackets and
such
like required on a production machine were ground or welded off, while all
existing Kawasaki welds were tidied up.
At the pointy end, Recycle Wreckers (more mates !)
supplied 43mm GSX-R750 forks, deliberately chosen for the fact that
they're not upside downies. True, an inverted set could have been used, but
they would have been more expensive and would have deviated too much from
the other intended aim which was to keep some resemblance of the original
Z (and let’s face it, despite all the mods, there is still a subtle hint
of the original Z in this bike). The GSX-R's triple clamps have been used too,
attached to the Kawasaki frame by a Kawasaki top bearing, sleeved step
nut, some bits from a taper bearing kit for Zs and a miscellaneous Yamaha
bottom bearing. Want more ? The front wheel is a highly polished 17" NSR 250
Honda item, slotted in between the Suzuki forks thanks to custom spacers
from the above mentioned Murray. The brakes too are a smorgasbord, combining CBR
400RR discs, with Yamaha FZR 1000 calipers mounted on polished custom
caliper mounts. Other really nice touches on the front end
include ultra light Goodridge Kevlar brake lines and custom anodized disc
rotor buttons. Incidentally, these buttons are another of the
items Alex’s Roo Racing enterprise manufactures. Goodridge lines are also featured on the rear of
this bike, where the VFR 400 rear brake assembly is employed as well as
the VFR wheel. With everything coming together nicely by this
stage, Kerry was kept busy performing acts of magic on all sorts of metal
surfaces - after all, that’s what Kerry’s K & D Chrome business is all
about. The frame, fully nickel plated, is a work of pure
art, but various hand made frame associated components, including Alex's
hand made engine mounting plates, foot peg brackets, front calipers etc,
were also polished, chromed or nickel plated and the results are breath
taking. The carbon fibre bodywork / fuel cell was created
by a bloke called Evan Wilson with the help of another individual who goes
by the name of ‘Animal’. The bodywork is one piece and includes a
fibreglass fuel tank that’s just a little down on the original steel
tank’s capacity due to all the electric’s and battery being located
underneath.The
seat, incidentally, is entirely self supporting without a sub-frame.
Don’t get the idea that this bike is just a show
pony though. With Alex being a former Yoshimura UK man, a full
stage three, racing spec' port and polish plus Wiseco 1045cc kit were
quickly applied. APE stainless steel valves and a couple of hard
faced Ivan Tighe 340c cams were included, the valves standard size on the
inlet and just a little oversize on the outlet. Surprisingly, but probably for cost reasons, it
was decided not to touch the gearbox, although a Barnett kevlar clutch was
installed. Internals aside, the exterior of this powerplant
has been altered significantly too. Thanks to a guy known as 'Scottish
Graham', hand made billet engine covers reduce the engines width by 25mm
on the alternator side and by 15mm on the points side. The revelation though, is that a VT 250 Honda
alternator is now on board !! The carbies are 34mm GSX-R units, running with K
+ N filters and attached to Z 1000J inlet manifolds that have been
painstakingly matched to the re-angled (i.e. straightened ) inlet ports on
the head. On the exhaust side, Peter Lawson of Legends
Exhausts has performed pure magic. There's certainly a hint of 916 in the system,
although it's the pairing of the cylinders that makes these pipes
different. Essentially, there are two separate exhaust systems on the
bike, cylinders 1 and 2 running into a single pipe and then muffler, with
the same arrangement for cylinders 3 and 4.
The heart of the matter is kept in perfect harmony
by a Boyer electronic ignition unit, which is in fact just one part of an
entirely custom electric’s set up based on NSR Honda components. As far as a full list of all the custom and
one-off parts is concerned - forget it ! The complete inventory is endless, although
perhaps the most unusual component is a push bike digital speedo! This is good for up to 260Kmh, has a trip meter,
fastest speed recorded (private road use of course ...), stopwatch etc,
etc. Again, this is another item Roo Racing are now selling, with various
length sensor leads. Oh, and for those who might think that Alex and
Kerry have produced an over length dinosaur, think again. The wheelbase is actually shorter than the
original Z900, while the bike weighs just 184kg (incl. 4 litres of fuel),
biased 55% to the front wheel. As this story was being completed, Alex and Kerry
came up with another set of clothes for their creation. The wheels are once again NSR Honda items, but
with distinct yellow powder coating mixed with polishing work. There’s also now a second one-piece bodywork
structure and front mudguard, perhaps giving the impression that there are
in fact two bikes here. It’s all about development really and undoubtedly
Alex and Kerry have a few more ideas to try. So what about nitrous oxide for the engine then
guys ?
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An earlier shot of the project
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