Z1000J - Teardown and Rebuild

[Exhaust Craft]

Yes it is a Kruger and Junginger swingarm and the price for that one is €558

The Carbs and Wiseco kit I got from Z Enterprises IMO their prices are very good, and I have just added a Dyna S ignition, coils and leads together with a push/pull twist grip with cables for the Mikunis, to the order

Even with paying for postage and import duty the parts are cheaper from USA, than UK or South Africa

But I do ask them to put the word "GIFT" on the invoice then it only incurs 10% import duty instead of 20%

NOW - where can I get a reasonably priced Oil Cooler kit


The 1000 looks even better finished,1100 with a titanium Piper style

and - Im perving over this Titanium exhaust - wonder how much ££££



here are the pics of the bike as it stands now.

[wild_zed]

My 3rd garage was finally finished in the middle of november, not wanting to start anything major before our summer holidays and shutdown I just stocked it up in preparation for the Z1000J rebuild, then today I got a hair up my @r$e and decided that now was as good a time as any


SO I Wheeled the "J" onto the new (imported from UK) Draper bike lift




Then I started stripping the beast.
The previous owner must've been a right pillock because none of the bolts are original.




4 hours later this is how it looked




Now I'll bring a trolly jack home from the factory to support under the frame and motor, then I'll remove the forks and swing-arm
Then Ill start sandblasting and preparing for powder coating and painting

I already have a ZX9 complete front end and wheels and the K&J swing-arm

The "J's" been standing neglected in the shed for far too long now, besides Ive also just got a 1980 H**** CB900F (genuine 15000km) for free from my brother that also needs a rebuild once the "J" is finished

[nw66]

what size are the mikunis and what model?

[paul doran]

great project
love the J,s

[Mr Puffin]

+1 on the J`s and Very tidy garage to work in, i hope your Dog does not mind the disturbance

[paul doran]

+1 on the J`s and Very tidy garage to work in, i hope your Dog does not mind the disturbance

yes garage is ace

Ihope to build My new workshop early this year

[wild_zed]

what size are the mikunis and what model?

I think they called RS Flatslides and they are 33mm
this is what Z-Enterprises (USA) recommended with the Wiseco kit and gas flow

+1 on the J`s and Very tidy garage to work in, i hope your Dog does not mind the disturbance

The dog loves it - she (10yr old Staffie) follows me around like a shadow when Im home, so she will normally just lie there and watch me tinker, but on Sunday it was 32deg C here, so it was a bit hot and when its hot she normally gets into the pool and just sits on the pool step - crazy hound

What you cant see in the pics as they are parked close to the roll up door are the two KTM's ~ 1 x 990SMT and 1 x 1190Adv - so it does get a bit crowded in the garage

[snotie1965]

Any progress ?

Have you decided on a pipe yet ?

[nick pearce]

Love it mate, keep up the good work.

[wild_zed]

Got some work done on the zed today, but it has now also created more questions than answers.

I could never have imagined what I would find until I opened the motor
The previous owner has forced 1/4" (BSW) witworth screws (bolts) into some of the 6mm tappet cover screws, then not one of the cam bearing shell carrier bolts had all 6mm bolts, some had 1/4" (BSW) witworth, two even had 8mm bolts in - what a fekkup
Fortunately I bought a Wurth time sert thread repair kit http://www.wurth.co.uk/hand-tools/threa ... master-kit so Ill be able to repair most of the threads

The cam gears have been "home slotted" and look like shite. something else for the shopping list.

Then when I took the head off, next surprise, the motor is fitted with 73mm Wiseco high comp pistons - ARGH - as I have already bought a set of 72mm Wiseco high comp pistons and rings
The 73mm pistons, rings and barrels look to be in OK condition.
I would really prefer to fit the 72mm pistons
Also the head looks as if it has been gas flowed and skimmed to max (ARGH)

Questions:
1. Can the Z1000J barrels be resleeved?
2. Are replacement sleeves available - if so from where?
3. Is there an easy way to remove the gudgeon pin circlips?

Options - is it worth resleeving the barrels or should I look for a spare motor ?

Either way - spare motor or resleeve - anybody looking for a set of 73mm WISECO high comp pistons and rings ??

Here are some update pics

[weaver]

you can re sleeve the barrels,I did the ones off my 1100r,sweated them out out in the oven

[Al]

http://www.wiseco.com/ProductDetail.asp ... AppID=7223
They are 10.25:1 so not so high comp as to cause problems.
Put some new rings on and sell the 72's
Youre new carbs will still be fine with these as they are only 1105cc so no big jump up.

On the head i would make damn sure before you go any further that the wanky bolts hav'nt collapsed the bucket wells inward which is the usual thing.
Feel the buckets in the wells and get an internal mic reading down the sides at various depths.
You will need to be very careful and lucky to drill, tap and re-thread the holes that carry the locating sleeves into the cam caps.
A very small window of opportunity to get them right so i would entrust to an engineering shop with the capability to digitise the correct locations of the centres of those holes.

One of those inlet valves looks to have been re-placed.
The one you have labelled valve#2
I would take a microscope to the valve guide because they can damage or in my case split the valve guides if the valve gets bent and the piston pushes it back up.
Over-revving in my case but with this engine, someone spent a lot of time and some money f#7'ing it up only to find it didnt run right. You need to find those reasons i guess before you commit to head work or more expense.
Those inlet valves do look suspiciously large. Could be as you say that the head has been fly cut.
Mine has been done once and the material removed from the bosses for the carb rubber mounts is about the same as mine.

Check the available depth (head half and barrel half together with thickness of new head gasket ) to ensure the location dowels dont bottom out when you button the head down. (the 6mm ones to extreme left and right outers)

Destroy the piston circlips to get them out and replace them when you get rings and gaskets.

AL

[Al]

P.S the spring steel clip inside the alternator outer case (the one that shields the wiring) is not properly located. It should be held inside the two raised 'buttons' cast into the bottom of the outer case when you look down into it.
It has been rubbing on the rotor.

AL

[wild_zed]

What a relief

I found a spare motor for GBP150, that is bog standard, the bike t-boned one of our notorious mini-bus taxis and the odometer only has 21000km on.
The cost of this motor is less than the cost of resleeving the barrels (installing new barrel liners) and re-drilling and threading the cam bearing shell holders and relocating the dowels

It looks completely unmolested, so much so that all of the fins are still 100% intact

The only downside now is the bike wont be number original, unless I use the existing casings.

[Is Vic There]

+1 on the J`s and Very tidy garage to work in, i hope your Dog does not mind the disturbance

How do you know he's got a dog and not just a collector of dog beds or it could be his and he sleeps in it due to 'her' finding out the real cost of the carbs