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Cut a little at a time until you’re happy with the bar width and everything fits. pm FAQ about KZ900 / KZ1000 Engines Larry Cavanaugh’s website used to have a forum and he had a useful FAQ page.The forum is gone and luckily I saved the FAQ and am reposting it here for the KZ community.If you pay attention to the information provided here, you can get the most bang for your buck and have a strong running Kawasaki as the end result. KZ900 - 1015cc KZ1000 - 1105cc [1075cc is suggested as the safe size without potential heating issues]Do I need to weld the crankshaft?That depends on what you’re going to do with the bike.Next, bolt the top clamps on, install the handlebar controls, hand grips etc. If these parts aren’t sanded the bike will probably run fine EXCEPT the turn signals might not work consistently or they might not work at all. Be careful when you’re shopping for handlebars because a lot of dirt bike bars are 1 inch and 1 1/8 inch diameter.
Money comes hard for most people so spending it wisely is always preferable. How big can I make the motor without larger sleeves?Rust and corrosion attack quickly, maybe that’s why there aren’t a lot of older classic bikes on Oahu.Superbike bars made with chromed steel look great and don’t cost much.When cutting the plug wires, if anything cut them longer than needed because you can shorten them later.If you cut a wire too short at the beginning, you might need to buy another set of wires or figure out if that short wire will work on another spark plug and switch wires out.