Zed 900 road racer .

Is Vic There · #346 PostAuthor: **Is Vic There** » Wed Mar 12, 2014 9:31 am

Yep fingers crossed all goes in your favour which I'm sure it will.

zed1015 · #347 PostAuthor: **zed1015** » Sat Mar 15, 2014 7:12 pm

Got the head back from welding this morning.
Had to do a bit of jiggery pokery with numbers 1 and 2 exhaust bucket bores, replace number 2 ex valve guide and fettle the seats slightly for the shells near 2 exhaust valve as the cam locked up when the cap was tightened due to the welding heat distortion.
Managed to find another o/s stainless valve which now matches the rest after a quick lathe session, clearanced the head for the Norris cams and re-built the whole lot with hd valve springs.
Quite a productive 8 hours.
Just have to bench shim the new cams tomorrow and it's re-assembly time ready for round two.

zed1015 · #348 PostAuthor: **zed1015** » Mon Mar 17, 2014 2:50 pm

It lives again .
Engine all back together, it started first kick and ticks over nicely.
It is running in the pic honest!
A little smokey on the over run but that should clear after a few miles ( if it doesn't then those cheap replacement rings are rubbish and i'll be inserting a set of wiseco's).
Had a short 10mph ride along the path and my fulcrum clutch works real well with it biting around half way in the lever travel with one finger operation.

A few pic's of the wiring etc I was gonna post before the camshaft incident.

Simple wiring in the tail with main fuse on insulated spades

Dyna coils converted to spade fittings with screwed on surface mounts

Rest of the wiring , horn and reg/rec just fits under the tank

Riders eye view of the Danmoto speedo. It's very clear but couldn't get a decent shot with the camera.

Just a few snagging jobs to do, a rear guard for the carbs, a bit of paint here and there and apart from sorting the jetting etc it's done

Paul Whitehouse · #349 PostAuthor: **Paul Whitehouse** » Mon Mar 17, 2014 3:06 pm

Brilliant work Rob...stunning looking Zed :up

Is Vic There · #350 PostAuthor: **Is Vic There** » Mon Mar 17, 2014 7:36 pm

So whats next then

Great job, knew it wouldn't take long for the engine to get sorted.

zed1015 · #351 PostAuthor: **zed1015** » Mon Mar 17, 2014 7:51 pm

Is Vic There wrote:So whats next then

Funny you should say that :lol:

I will be starting another build thread soon :wink:

Royalratch · #352 PostAuthor: **Royalratch** » Mon Mar 17, 2014 7:58 pm

Awesome.

Rob - where can I get hold off the nice rubber sheaths you have used for your Reg Rec and Coil cables?

zed1015 · #353 PostAuthor: **zed1015** » Mon Mar 17, 2014 8:04 pm

Royalratch wrote:Awesome.

Rob - where can I get hold off the nice rubber sheaths you have used for your Reg Rec and Coil cables?

The clear spade ones are from Vehicle wiring products but the reg/rec one is robbed from my collection of bike wiring harnesses I keep for just such an occasion.

Z1parR · #354 PostAuthor: **Z1parR** » Mon Mar 17, 2014 8:08 pm

It's an evil looking bastard that is matey :up

snotie1965 · #355 PostAuthor: **snotie1965** » Mon Mar 17, 2014 8:13 pm

What can i say? Brilliant job !! Top Marks .......

zed1015 · #356 PostAuthor: **zed1015** » Mon Mar 17, 2014 9:56 pm

Not quite there yet :roll:

.
Looks like the race alt is not kicking out any charge and has drained the Lithium battery which could be knackered if the voltage has dropped too far.
Just hope an overnight charge saves it.
Might have to make my own set up but at least I know it'll work.

Sick of ELECTREX selling me crap :evil:

LondonZ1 · #357 PostAuthor: **LondonZ1** » Tue Mar 18, 2014 5:21 pm

Lithium Ion batteries are usually OK after a deep discharge (unlike nickel metal hydride) so fingers crossed. I bought a special Li Ion optimate which has rescued my Super B after I let it go flat. I leave it on permanent trickle charge now.

zed1015 · #358 PostAuthor: **zed1015** » Tue Mar 18, 2014 7:24 pm

The info with this Shorai says not to let it let get discharged or it will be kaput.
Maybe they are covering their backs.
Luckily the overnight charge has worked and it's ok.

Big Fluff · #359 PostAuthor: **Big Fluff** » Wed Mar 19, 2014 1:52 pm

Excellent build that Rob, and bad luck with the motor 1st time round.
I too had problems with tappet bucket bores causing a tight spot after welding.... this led to a bent valve on start-up for No.4 inlet.
Mine too is now sorted and finished.
Love the clutch mech. very nice.

zed1015 · #360 PostAuthor: **zed1015** » Wed Mar 19, 2014 3:48 pm

Big Fluff wrote:Excellent build that Rob, and bad luck with the motor 1st time round.
I too had problems with tappet bucket bores causing a tight spot after welding.... this led to a bent valve on start-up for No.4 inlet.
Mine too is now sorted and finished.
Love the clutch mech. very nice.

I've actually pulled the top end apart again :lol:

Wasn't happy with the way it smoked and it's had long enough to burn off any excess oil etc from the rebuild.
I think the gamble with the cheap rings was false economy so rather than wait for my suspicions to be confirmed Gremlin are sending a wiseco kit overnight and i'm having it bored out over the weekend while i'm away camping.
Once that is done and dusted i'll tackle the charging system and then it's just leaves the setting up.

Zed 900 road racer .

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