Sport to Motard.

[MZ in Oz]

Hi, I've had a MZ Tour for 15 years and many klms, picked up a neglected Sport a few years ago which I revived and rode for awhile.
Have been away travelling around Oz for past 12months and now back home and catching up on some workshop time.
Project is converting the Sport to a Motard.
Picked up a set of XT600 forks for front end which slotted straight into the MZ triple clamps, forks rebuilt with a stroke reduction of 22mm,
Grimeca caliper fitted XT forks pefrectly.
Fabricated new footpeg and lever brackets bring position down and forward, shorter dogbones to raise rear.
Air box/batterybox removed to make room for exhaust system running up through frame.
Have been careful not to cut and alter any fame our mounts so if required I can swap back Sport mode down the track.
Looking for MAstiff/Baghira low front guard.

Footpeg/lever mountings

XT Forks

[manxie]

Hi. Did you have to do anything to the bottom of the forks to make the front wheel fit? Crackin` idea!!

[MZ in Oz]

Just removed speedo drive and machined some spacers to centre the wheel and modified an axle I had laying around
and also had swap the legs left to right as XT has disc on left side.
Have also made forkbrace. Exhaust is next big effort, have ordered bends which should arrive this week.

[manxie]

Nice one, excellent job!! cheers.

[MZ in Oz]

First couple of bends in place. Misjudged how many bends I would need and have had to order a couple more.

[MZ in Oz]

I've been doing a little more on the motard conversion. Pipes have been completed and fitted up, new handlebar and I had a go at forming up a ally front guard.
This is my first attempt at sheet metal forming and I'm fairly happy with it, next one will be better.

Exhaust pipes routed through frame.

Sexy blue handlerbar.

Front guard knocked up from 1.6mm Al.

[DAVID THOMPSON]

that looks good
..but where i live it will pack full of wet sloppy SNOW and need removed to go on home

[MZ in Oz]

A few more bits and pieces on the build.
Got my headlight mounted so I thought I would finish connect all the electrics
and see what was or wasn't working. All I did was plug it all back together nothing
had been changed from when I last rode the bike, well I had voltage where there shouldn't
be and none where it should, lights coming and going on and off.
Quick check with multimeter found all 3 wires going to ignition switch had voltage,
should have been only red with volts. Started stripping back wrapping looking for short, nothing found.
Wiring diagram is in German, translate it and found there are some hidden diodes. Managed to find them
one along the neutral/sidestand switch has broke corroded wire and not passing current. Found the
other 2 and checked them for continuity, same no current either direction.
Wire loom is now all stripped back and in process of all connections being redone and new diodes.
Fingers crossed it all works.

Side scoops on radiator.

Headlight and screen.

[tigcraft]

Not been on here for ages and just spotted this.
What an interesting challenge, I've never seen this done before and I'm quite impressed. Hope it goes as planned.

[MZ in Oz]

Project is just about complete, air filter and tyres are final items to be fitted.
Looking for set of wire wheels 17"/19" to fit up down the track for a better off road
experience.