520 conversion for 1977-1980 Z1000's

[Gosling1]

This is a really simple how-to guide to installing a 520 chain & sprockets to your big old Z1000.

#1 - This conversion is only suitable for the following models:

Z1000A1 - A4, Z1000D1 (Z1R), Z1R MkII, Z1000MkII, Z1000H.

#2 - Basic specs of the OEM sprockets for these models is as follows:

Front - spline count 13, inner diameter 21.7mm, outer diameter 25mm
Rear - PCD 104mm, mounting bolt diameter 10.5mm, hub diameter 80mm


OK, that is the basics covered. All you need to do this conversion is this:

Bin all the OEM 630 shit - chain & sprockets, but keep the front sprocket mounting nut and splined lock washer, and all the rear sprocket mounting hardware.
NOTE - Buy another splined lock washer from Kawasaki.

Purchase the following sprockets from your local tyre dude:

Front sprocket - JTF512. Rear sprocket JTR1478.

These sprockets are the 520 conversion sprockets for the P1-P8 model ZX7R's between 1996 and 2003.

NOTE - Do NOT buy the OEM sprockets for this model - they are 530 sprockets. ( they will fit your Zed but thats not the point )

Fit one of the splined locking washer - flat (ie - don't fold any tabs) - straight onto the output shaft.
Fit the front sprocket.
Fit the other splined lock washer onto the output shaft over the sprocket.
Do the nut up tight - you can get it tight enough without having the chain fitted or using the rear brake or any of that palaver - just place a small piece of timber under the sprocket so it holds the sprocket while you tighten the nut. It just needs to be snug.
Then fold over 2 opposite sides of the lock washer so it locks the nut in place. The nut does all the work.

Fit the rear sprocket - no differences here from the OEM 630 sprocket. It will just bolt straight into place.
Fit the chain. I used an X-ring chain, nothing too flash or expensive. 122 links you need to cut off maybe 6 depending on the gearing.

Which brings me to gearing. OEM 630 gearing on these models varies, but 15/35 is not uncommon.

You cannot use this gearing with either 520 or 530 conversions. 17/40 is close, but after some experimentation I am going to 17/38 on the Black Pearl for longer legs on the highway. Currently it is fitted with 17/41, so it is good off the mark !

That's it. Easiest conversion known to mankind. 1 additional part only ( the extra splined washer spaces out the front sprocket to the correct position).

Heaps less unsprung weight, and less power loss through that massive heavy boat-anchor chain known as 630. It is so much overkill.

Have fun

[h.b.bear]

[Phil]

Fuck yeah..........mouth is now watering

[hoffy]

Do i get to havago tomoz??

[Gosling1]

looks like next time Hoffy - bit wet today

cheers cnut.

[Kwakked Up]

Thanks Gos

You have given me sooo much info for my project my head is full. You are like a freakin walking encyclopdedia

Is there a way of saving this stuff on here so I can access it later, like that one you did on sticking a relay into the electricals for a more direct power supply to the coils?

cheers

[Gosling1]

.......Is there a way of saving this stuff on here so I can access it later, like that one you did on sticking a relay into the electricals for a more direct power supply to the coils?......

no probs mate

This thread is now a sticky - so it will always be at the top of the page for threads in Classic Kawi discussions - you won't have to go digging for it.

[Kwakked Up]

thanks for that, damned good thing that sticky

The only way I found of making them easy to find was to make some lame post on the thread so i could find them in my post section

[Eastoe]

The rear sprocket is also good for the 82 GPZ750.
http://www.jtsprockets.com/catalogue/model/5246