{"id":49996,"date":"2017-12-20T19:20:49","date_gmt":"2017-12-20T10:20:49","guid":{"rendered":"https:\/\/www.decoboco.info\/en\/?p=49996"},"modified":"2026-09-24T13:44:54","modified_gmt":"2026-09-24T04:44:54","slug":"frame-build-kz1000-kz1000mk2-z1r-step-fabrication","status":"publish","type":"post","link":"https:\/\/www.decoboco.info\/en\/20171220\/decoboco-cars\/kz1000\/frame-build-kz1000-kz1000mk2-z1r-step-fabrication","title":{"rendered":"\u2470 Frame Build: KZ1000\/KZ1000MK2\/Z1R. Step Fabrication"},"content":{"rendered":"
\"\"
\nIt’s still temporary, but it’s enough to imagine. <\/div>\n
<\/div>\n
<\/div>\n

<\/p>\n

\"\"
\nI don’t have the financial means to drop tens of thousands on an aftermarket backstep.
\nI wouldn’t make one for a current-generation supersport, but older bikes have simpler structures. I had some scrap material from 2017, so I used that to drill holes and so on.<\/p>\n

Since it’s for myself, I went the tedious route: drill press, contour, then sander.<\/p>\n

\"\"
\nI hate the base plate flexing, so I made it 15mm thick.
\nThe finish looks rough in the photo… well, I’m not even sure I’ll use this yet…<\/p>\n

\"\"
\nThat’s what I got. (Left and right)
\nI won’t add a spacer on the back. Contact areas are relieved with a milling cutter along with lightening. I think fewer components and simplicity are best.<\/p>\n

\"\"
\nThe Z uses a step fastening with a stud\u2014basically a shoulder bolt plus nut setup.
\nM10\u00d7P1.25 & shoulder is 12\u03c6.
\nSo inserting a standard spacer 10\u00d712\u00d715 would be good for the bolt too.<\/p>\n

\"\"
\nThat’s the way to go. Buying is better. It’s wasteful to use rod stock and inserts.<\/p>\n

\"\"
\nNow I’ll make the step bar. I’ll turn the ball down\u2014if I make it completely round, welding is a pain, so I’ll leave it slightly flat.<\/p>\n

\"\" \"\"
\nThree-piece structure and the step is done. I don’t like it unless my boot sits completely on it, so I made it longer.<\/p>\n

\"\"
\nPut the rare RGB500 rubber on and you get that vintage feel.
\nSure, it feels like a superbike from back then, but I really think it was a great era with everything analog and wide open.<\/p>\n

\"\"
\nI tried fitting it temporarily. Yeah, it looks nice and understated.<\/p>\n

\"\"
\nNext step. I’ll make the pedal. No time, no budget. Tough situation.
\nI had some 5052 aluminum that was a bit thick, so I’ll use that to make the pedal.<\/p>\n

I’ll cut round holes where the pedal welds. A hole saw is the safe choice. For a lazy guy like me, a shear blade\u2014punch in, pull out\u2014about four times and it’s done.<\/p>\n

\"\"
\nI removed an oilless bearing (used GSXR1100). I machined the spacer that becomes the pedal shaft to +2\/100, heated it, and pressed it in by hand.<\/p>\n

\"\"
\nThen it’s cut the pedal plate, grind it, bend it, polish it, and so on.<\/p>\n

Whether it’s a chamfer or a radius, a clean edge makes all the difference. Back in the day I’d do sloppy chamfering with a Belsan, and honestly, I’m embarrassed thinking about it now.<\/p>\n

\"\"
\nI matched the spacer dimension to the original and then realized it was too thin.
\nTaking it slow worked out fine since it’s aluminum.<\/p>\n

\"\" \"\"
\nThat’s how it should turn out.<\/p>\n

 <\/p>\n

The right side will be a bit gimmicky brake. Don’t you think a brake master looks cooler when it’s as hidden as possible?<\/p>\n

That’s what I meant by the other day’s lucky day.<\/p>\n

 <\/p>\n","protected":false},"excerpt":{"rendered":"

It’s still temporary, but it’s enough to imagine.<\/p>\n","protected":false},"author":2,"featured_media":49980,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"pochipp_cv_data":"","swell_btn_cv_data":"","footnotes":""},"categories":[38],"tags":[157,166,193,115],"class_list":["post-49996","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-kz1000","tag-customization","tag-production","tag-starting-with-the-frame-kz1000-kz1000mk2-z1r","tag-z-aircooled"],"_links":{"self":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/49996","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/comments?post=49996"}],"version-history":[{"count":0,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/posts\/49996\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media\/49980"}],"wp:attachment":[{"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/media?parent=49996"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/categories?post=49996"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.decoboco.info\/en\/wp-json\/wp\/v2\/tags?post=49996"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}