Crafting the Ultimate: Kawasaki ZEPHYR1100 Custom by Shabon Dama

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Shabon Dama's ZEPHYR1100

"The Kawasaki ZEPHYR1100 is, in a word, a bike with a legendary character," says Mr. Takikawa, the representative of Shabon Dama, who capture its essence. So, what would you do to customize the Zephyr now? "If you start with the 1100 from the first step, you will probably feel that it is heavy despite its power, so I would recommend changing the wheels first. Next, focus on the front and rear brakes to enhance braking power, touch, and operability. Then, address the front and rear suspension and the stem area. It would be better to address these aspects simultaneously with the wheels if you plan to change the front [18→]17 inch. Balance is also important in this area, so consulting a reputable shop would be the best approach. If needed, I would also consider adjusting the riding position. By taking care of these aspects, you can enjoy the bike for a long time. As the mileage accumulates, also consider performing an overhaul."

It is common to encounter cases where the suspension area is modified to this extent as the owner loves the bike and has been riding it for a long time. If you are considering starting now, it's advisable to begin with a well-defined plan. This bike could serve as a reference for such a case. "It is owned by a customer who I have known for 20 years and he has been riding it for that entire time. Over this time, the bike has undergone several specification changes, with the current version being a 'ZEPHYR1100 with all my heart'. The aforementioned modifications have been thoroughly implemented, including an engine overhaul and conversion to 1107cc and the rest is almost a full menu. The tank was replaced with an aluminum one, repositioned slightly to allow for an increased steering angle even with the clip-on handlebars. The lower part of the fork was replaced with a larger diameter fork with the ZRX1200's φ25mm axle. Our standard heavy customization menu was also incorporated." In reality, this bike handles as nimbly and lightly as any well-crafted custom example. Mr. Takigawa adds that the individual parts are also worthy of attention. One example is the new exhaust system. "It is a '3D weldcrafted' full titanium EX, a collaborative product with Sanctuary. Our goal was to create something suitable for bikes that have undergone detailed customization. Therefore, we developed this ultimate piece, catering to those who own such bikes, allowing them to appreciate its exceptional quality." The exhaust system was designed to embody the "legendary character" mentioned earlier. This involved pursuing aspects like braking precision and applying an Okumura tune to tailor the suspension to the owner's preferences. The Zephyr boasts an array of custom parts, much like this exhaust and aluminum tank. How you select and install these parts will alter the bike's appearance and overall finish. This is the key to enjoy riding it for an extended period of time.

Handle

The stem is a WHEELIE billet, and the fork offset was changed from the stock 45 to 30mm to match the 18 to 17 inch front change. The handlebar is clip-on and the left and right master cylinders are equipped with Brembo Radial Pumps. The bar handle brackets have been converted to brackets for an additional Active Digital Meter.

Bodyworks

The fuel tank is replaced with an aluminum fuel tank that eliminates the dents in the knee grip area, contributing to weight reduction and styling improvement.

The exterior parts of the side covers and tail cowl, and the seat, which is a single type with a different interior, have been replaced with original Shabon Dama products.

Engine

The engine was modified from 1062 to 1107cc with Wiseco 75mm pistons and Yoshimura ST-2 camshafts. The exhaust system is a 3D Weldcraft Titanium, a limited edition collaboration with Sanctuary.

Intake & Exhaust

The carburetor is Yoshimura-Mikuni TMR φ38mm MJN (Multiple Jet Needle) + DNA filter.

Chassis

The step is a WHEELIE billet, as are the engine clutch/pulser/generator covers and the hydraulic clutch cylinder.

The pedals of the steps are knife-edge shaped. The frame is stock, reinforced in 7 locations and powder coated.

For the bottom piece of the ø43mm Ohlins front fork, a WHEELIE ZRX1200 axle was selected to increase the axle diameter from ø20 to ø25mm.

The swingarm is made of WHEELIE's 7N01 H-shaped cross-section material, and the rear brakes are Brembo opposed 2P calipers supported by a WHEELIE bracket.

The rear shocks are Ohlins Legend Twin with Okumura ME tuning just like the front ones. The wheels are forged aluminum GALE SPEED Type-R wheels, with 3.50-17/5.50-17 front and rear 17 inch instead of the stock 3.00-18/4.50-17 for improved sports performance.

Gallery

Specifications

Part	Details
Engine	WISECO φ75mm Piston Kit 1107cc YOSHIMURA ST-2 Camshaft WHEELIE Zephyr1100 3D Clutch Cover WHEELIE Zephyr1100 Generator Cover WHEELIE Zephyr1100 Hydraulic Clutch Cylinder
Carb / Intake	YOSHIMURA TMR-MJN Carburetor DNA Moto Filter per Model
Exhaust	Shabon Dama 3D Weldcraft 4-1 Exhaust
Frame	WHEELIE BIG H-shaped Cross-section Swingarm OW-B Type Standard Type End
Brake	BREMBO RMC Brake Master Cylinder BREMBO CNC Axial 4P Caliper PLUSμ Disc Rotor BREMBO CNC 2P Caliper
Wheels	GALE SPEED TYPE-R 3.50-17 GALE SPEED TYPE-R 5.50-17
Suspension	OHLINS Upright Front Fork RWU WHEELIE Zephyr1100 Ohlins Upright Fork Machined Bottom Case OHLINS Rear Suspension
Steps	WHEELIE Billet Step Kit
Handle / Steering	WHEELIE Street Triple Tree for Zephyr1100, 30mm Offset BREMBO RMC Clutch Master Cylinder ACTIVE Digital Monitor V3 Rev & Temp
Oil Cooler	ACTIVE Round Oil Cooler Kit
Seat	Shabon Dama Custom Order Seat
Bodyworks	Shabon Dama Carbon Side Cover Set for Zephyr1100 (Reinforced Type) Plain Weave Carbon Shabon Dama Carbon Tail Cowl for Zephyr1100 Plain Weave Shabon Dama Original Aluminum Tank

About Shabon Dama

Shabon Dama offers many custom parts mainly for Kawasaki Z1, ZEPHYR series, GPZ serices and other retro bikes. They are offering unique and originality-focused products such other can't copy. The full customization of your Kawasaki retro, vintage bike, Shabon Dama is the brand worth considering for JDM originality!

Shabon Dama brand page

Original Source of this Article

Heritage & Legends