Slow moving Z650 cafe racer project

[aPeMunky]

Well this project is certainly living up to it's name!

Everything took much longer to deliver or manufacture meaning that when parts finally arrived I was really busy moving to a new company at work, then Xmas etc...

Finally got the chance to lace up the new rims, will have to true them later in the week



Cleaned up the hubs and had a oil seal and spacer made to cover up the speedo housing



Adapters made to connect the SRAD forks to the original Z650 spindal



Z650 stem fitted into the SRAD yoke using GB's method, also ignition barrel holder machined off to give the top yoke a cleaner line



Not sure the new rear rim and 150/18 tyre will clear the swingarm that came with the bike, it looked a bit tight but will test again when the tyre is fitted. Bought a ZX6R swingarm just in case but that will need modding to fit. If I need it i will probably go for a wider rear tyre at some point.



Any idea what make this Z650 Swingarm is?



Next job is to fit this lot to make a rolling chassis then get the new disc hubs made so I can scooter around whilst I play with the lump.

[aPeMunky]

Progress...

Wheels trued





Front wheel, tyre & Forks fitted



When I got them balanced they fitted ugly silver weights which ruined the look of the wheel so searched the net and bought these instead, Dynabeads.

http://www.dynabeads.co.uk/autobike.php

Hope they work well, it will probably be a while before I get to find out, sound great though and drastically improved the look of the wheel. They work with tubeless & inner tubes, very friendly guy whom is happy to discuss the product.

Front discs have been sent away to get new offset centres made (about 30mm required) to mate to the Z650 hub, it's going to take about 4 weeks.
SRAD brake calipers rebuilt, I'm really hoping that a single front disc will provide sufficient stopping power as it improves the look of the front end (it will definitely be better than the pants OEM twin disc set up) but I'll fit both discs to start with.

[750steve]

Oh dammit, wish i had seen this way earlier. You can press the Z650 stem out FROM THE BOTTOM by grinding off the weld on the underside of the yoke then pressing it out, it moves pretty easily. I pressed mine out & fitted it to ZX10 yokes. I milled the ZX10 stem out like a cup for the 650 stem to push into then welded it on the inside.

Modern bike stems usually press out FROM THE TOP

[aPeMunky]

New rear rim & tyre was too fat for the braced swingarm so had the Zx6r J one modded to fit, all tabs & mono shock mount removed.
Just have to fab the twin shock mounts and work out where I want them.



Nice snug fit, just had to get a sleeve made and pressed in so I could use the original swingarm bolt and a 'top hat' spacer made to fit the other side to eradicate any play.



Sleeve



Monoshock mount ground off, shame the welding is so bloody ugly, more work with a grinder to come.



Gorgeous new axel bolt made to mate & space the original hub to replacement swingarm, a thing of beauty...

[aPeMunky]

Getting it all aligned, freezing cold day in the garage today, masking tape, ruler and bits of string









all very frustrating until I borrowed this useful toy

[aPeMunky]

The bike came with these Marzocchi replacement twin shocks



They look rebuildable as it would appear that they can be unscrewed...



But I spoke to a local suspension company and they doubted whether parts would still be available and whether they could be rebuilt to my requirements (much lighter bike etc)

If they could be rebuilt do you think it would be worth it or would I be better off buying Hagon replacements?

http://www.bike-revival.co.uk/exp.html

The 2810's also have damping adjustment, I would want stainless body with black spring which puts the cost up to £250 plus another £20 to have them designed to my requirements.

What shocks does anyone recommend? Don't want to go big on budget (ohlins etc) as costs are spiralling and will need to rework the forks as well.

[Flying Tiger]

Looking good, love the wheels!

[Crofty]

Good work lad

[Padders]

Loving this post keep it up. I would recommend Hagon's decent price and they will custom make to your requirements.