Starting with the frame: KZ1000/KZ1000MK2/Z1R. Aluminum swingarm adaptation

Kawasaki KZ1000/KZ1000MK2/Z1R—the Z-series bikes always struck me as having a pretty short swingarm at first glance. I don’t get to work on them that often, but the other day I measured a customer’s pivot axle center and came up with around 500mm.
First, I want to see what the profile would look like if we stretched it out—full scale.
I’m using a tape measure, so it’s pretty rough. Starting from 10, I’d say it’s around 515–520mm.


Since this is a Yamaha monoshock swingarm, there are unnecessary links and torque rod mounts, so I’ll cut those off.


After cutting, I go at it with a roughing tool, but the mill is too small and I have to reposition it over and over. After about an hour of that hassle, I decided to change tactics.


There really are some amazingly convenient things in this world. I was surprised to find a tool I’ve never used before just sitting there. For aluminum, this is the one—really educational.

This spot looks a bit bare, so maybe I’ll weld on a burled plate.


This is the lower suspension mount I made as a test the other day. Back in the day, they’d bend sheet metal like this. Nowadays, everything’s billet and way over-engineered—really beefy.

Period-correct sheet metal bending in a U-shape—light but solid.


It’ll look pretty cool mounted like this.


This is my GS1000S. I’m thinking about making the square plate in titanium too.

Two weeks later? And the content’s thin! My energy’s kind of… flagging.

 

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