Red Sled
Champagne Performance On A Beer Budget

By Bob Feather

A tight little group of leather-clad Riders was gathering around a bright red bike in a sea of motorcycles. It was Sunday morning at Marcus Dairy, and I moved in closer to see what the clamoring was all about. There it was: a pristine 1977 Kawasaki KZ1000 LTD that had been thoughtfully upgraded with modern features, yet it retained the styling of its heritage, a distant era known as the ’70s.

While there is no insane metal fabrication or $5,000 paint scheme on this bike, the beauty of it lies in the simple and tasteful execution of a plan. Owner Larry Mincow likes to tinker. So much so, in fact, that he’s known as “Tinker” among his friends and acquaintances. Got a toaster, lawnmower, or computer that doesn’t work? Tinker can fix it.

So, I asked the obvious question: Why pick a 1977 KZ1000 LTD for a project bike? “I like the classic lines and exposed engine of an old standard bike,” says Tinker. “All sportbikes pretty much look alike these days. Too often, the only way I can tell them apart is to look for the name badge.”

Instead, Larry set his mind on building a retro bike that would deliver big torque and good handling without draining his checking account. In the spring of 2003, he began his search for a bike to serve as the platform for this project. By late September, he struck gold in the form of a low-mileage 1977 KZ1000 LTD, which he would build into the screaming-red retro burner you see here.

For 18 years, the once-mighty KZ had hibernated under a cover in the owner’s garage. Over the years, brake fluid had been leaking onto the gas tank, frame, and engine, eating through paint and staining the metal. The engine oil had long since morphed into a dark cottage cheese-like substance. The fuel tank and carburetor float bowls wore a thick coat of stinky, aged petroleum varnish. Yet, with only 4,000 original miles on the clock, Larry deemed the old Kaw a good foundation to build upon.

Larry, being a motorhead from way back, wasn’t satisfied with the stock engine performance. So, off it went to Xtreme Motorsports in Danbury, Connecticut, to get the cylinders bored to accommodate an 1105cc Wiseco piston set. And while they were at it, they ported and polished the heads and fit them with a new set of oversized stainless steel valves.

Well now, they couldn’t do all that headwork without modifying the intake and exhaust systems, too. So, they bolted on a set of velocity stacks to flow more air into a heavy-breathing bank of 36mm Mikuni flat-slide carbs. Exhaust gases were sent on their way through a new Star Racing Pro Street Pipe. I love to hear these air-cooled engines howl through an old-style megaphone pipe. And the throaty roar from the carbs when you whack the throttle to lift the slides — pure old-school hot rod!

Due to the increased horsepower on the top end, the crankshaft down below needed some help to handle the load. Some of us remember how, under the stress of added horsepower, those old pressed-together crankshafts used to spin their counterweights out of time. Larry had the crankshaft welded for strength and then balanced to reduce vibration. There aren’t enough o’s in “smoooooooooooth” to describe how this engine runs. It now grunts out a claimed 120 horses, compared with the stock figure of 75. Respectable by any standard!

With the engine work done, Larry turned his attention to the rolling chassis. While the frame remains stock, he had a few tricks up his sleeve to improve the handling and braking power of his project bike. Rather than flip through the pages of the latest high-dollar performance parts catalog, Larry stripped parts off a 2000 Kawasaki ZR7 donor bike he’d bought cheap.

The entire ZR7 front-end assembly, including forks, trees, fender, wheel, and brake system, replaced the spindly KZ front fork. The larger fork tubes and wider front wheel from the ZR7 dramatically improved handling. And when it’s time to scrub off speed fast, the superior ZR braking system does a great job of reining in all that extra horsepower. The swingarm was custom-made by Xtreme Motorsports and features a 2" stretch over stock and greater rigidity. It also accommodates the ZR7 rear wheel and brake setup. Sweet! The result is an improved rolling chassis that looks good and performs better. But the best part is that all of these chassis mods were done for less than the price of just one billet wheel from one of those pricey performance catalogs!

With the engine and chassis work complete, Larry had to create a plan to visually tie this whole project together. No less than 78 individual parts were sent out for black powder coating. In fact, all the black parts on the bike are powder-coated, with the exception of the engine cases, cylinders, and head. The tank, front fender, rear cowling, and side covers got a thick, vivid coat of arrest-me red paint. Add a big chrome megaphone pipe and all those black powder-coated pieces, and this bike will stand out in most parking lots and bike shows.

The finished product stays true to the original lines and styling cues that make classic open-engine bikes so cool. The modern features that Larry added make the bike more fun to ride and a lot more fun to talk about. This great-looking, old-school bike has a big bark and the horsepower to back it up. And the beauty is in the details. Many people would walk right past this bike and simply dismiss it as old. To those of us who remember the wicked handling and underpowered ’77 KZ, Larry’s version of this bike is as cool as the other side of the pillow.

A little ingenuity and ambition can go a long way. Larry’s bike sits here complete, for a grand total of just $8,500. That’s pretty cheap, especially when you consider that it is one of a kind and a real standout from the crowd. RB

TECH SHEET

Owner: Larry “Tinker” Mincow

Home: Danbury, CT

Builder: Xtreme Motorsports and owner

Year/Model: 1977 Kawasaki KZ1000 LTD

Time to Build: Six months

Cost to Build: $8,500

Painter: Carland Auto Body, Danbury, CT

ENGINE

Displacement: Bored to 1105cc

Crankshaft: Welded and balanced

Pistons: Wiseco 1105cc set

Heads: Stock, ported and polished

Valves: Stainless, oversize

Cams: Web Cam Z2

Carbs: 36mm Mikuni flat-slides

Air Cleaner: Velocity Stacks

Exhaust: Star Racing Pro Street Pipe

Final Drive: Chain with taller gearing

CHASSIS

Frame: Stock

Front Suspension: Kawasaki 2000 ZR7

Swingarm: Custom-made by Xtreme Motorsports, 2" stretch

Rear Suspension: Progressive 412

Front Wheel: 2000 ZR7 17 x 3.5"

Rear Wheel: 2000 ZR7 17 x 5"

Front Brakes: 2000 ZR7 calipers

Rear Brakes: 2000 ZR7 caliper

Front Fender: 2000 Kawasaki ZR7

Rear Fender: Stock

ACCESSORIES

Headlight: H4 halogen bulb

Taillight: Stock

Turn Signals: Custom Chrome

Fuel Tank: Stock

Handlebars: Custom bars and risers with internal wiring by Xtreme Motorsports

Seat: Stock, reupholstered by Bethel Upholstery, Bethel, CT

Pegs: Stock

Hand Controls: Stock and ZR7

Mirrors: Stock

Foot Controls: Stock

Tag Bracket: Stock

Paint: Color, Volkswagen Tornado Red by Carland Auto Body, Danbury, CT

Front Tire: Metzeler Sportec M1, 120/60-17

Rear Tire: Metzeler Sportec M1, 170/60-17