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Project Z900 A4 - Restoration - Pic Heavy
Moderators: KeithZ1R, chrisu, paul doran, Taffus
Hi alex good to see you
Jay and his good lady wife last week.
Glad your happy with your cases.
Wait till you see padders fully engraved
Set even if I say so myself they
Look really nice.
Start on the chrome work next week
Send the mudguards to griffs get the
Inners blasted get all the rust out.
Start stripping the other chrome bits.
Jay and his good lady wife last week.
Glad your happy with your cases.
Wait till you see padders fully engraved
Set even if I say so myself they
Look really nice.
Start on the chrome work next week
Send the mudguards to griffs get the
Inners blasted get all the rust out.
Start stripping the other chrome bits.
Making the world a shiny place with a factory finish
That looks the boll*x, quality finish 
(It would be interesting to see all the 'cleaning' finishes side by side; vapour,soda, ceramic etc etc).
Looks great, keep up the good work,
cheers freddy
(It would be interesting to see all the 'cleaning' finishes side by side; vapour,soda, ceramic etc etc).
Looks great, keep up the good work,
cheers freddy
Punctuation, Spelling and Grammar will be used sparingly. Due to rising costs of inflation.
“It's not me who can't keep a secret. It's the people I tell that can't.â€Â
freddyz1r
PUM 329
“It's not me who can't keep a secret. It's the people I tell that can't.â€Â
freddyz1r
PUM 329
September week 4 update.
Stripped the hubs out this week, plenty of corrosion.
Hubs washed and ready for ceramic cleaning.
Rims are good and straight & ready for re-chroming, very few marks.
Note the foreigner in the middle, anorak points awarded for naming which model of Kawasaki it fits.
A quick trip through the blaster and were ready for polishing and plating.
Struggling to get the forks apart, I'm threatening them with the die grinder
Stripped the hubs out this week, plenty of corrosion.
Hubs washed and ready for ceramic cleaning.
Rims are good and straight & ready for re-chroming, very few marks.
Note the foreigner in the middle, anorak points awarded for naming which model of Kawasaki it fits.
A quick trip through the blaster and were ready for polishing and plating.
Struggling to get the forks apart, I'm threatening them with the die grinder
Fork Update.
Took a while to strip down the forks for the refurb.
Not being able to see down the tube I couldn't see what I was up against - the broom handle trick didn't work.....
I re-assembled the fork and air gunned the bottom bolt - no good it just kept spinning.
Sent a socket down the tube with some plasticine in the end to find what the shape was down there.
After seeing the shape required I sent an old socket down with some chemical metal in it to make a socket to fit.
After leaving it for half an hour to let it set hard - the bottom bolt air gunned out without a hitch, A strange shape, quite logical really.
Happy days
Took a while to strip down the forks for the refurb.
Not being able to see down the tube I couldn't see what I was up against - the broom handle trick didn't work.....
I re-assembled the fork and air gunned the bottom bolt - no good it just kept spinning.
Sent a socket down the tube with some plasticine in the end to find what the shape was down there.
After seeing the shape required I sent an old socket down with some chemical metal in it to make a socket to fit.
After leaving it for half an hour to let it set hard - the bottom bolt air gunned out without a hitch, A strange shape, quite logical really.
Happy days
I find a gator grip socket handy for this type of stuff.
they work brill. And are worth carrying in your underseat toolkit.
http://www.ebay.co.uk/itm/like/15142862 ... rid=229508
they work brill. And are worth carrying in your underseat toolkit.
http://www.ebay.co.uk/itm/like/15142862 ... rid=229508
Clever hinckley 
like your thinking
the gator grip is ok, but in my experience with them is, if somethings a bit stubborn the little pins 'snap' out while flexing.(I think I'm on my 3rd
)
Cheers freddy
like your thinking
the gator grip is ok, but in my experience with them is, if somethings a bit stubborn the little pins 'snap' out while flexing.(I think I'm on my 3rd
)
Cheers freddy
Punctuation, Spelling and Grammar will be used sparingly. Due to rising costs of inflation.
“It's not me who can't keep a secret. It's the people I tell that can't.â€Â
freddyz1r
PUM 329
“It's not me who can't keep a secret. It's the people I tell that can't.â€Â
freddyz1r
PUM 329
October week 1 update.
Time is a precious thing at the moment so progress continues to be slow.
Lots of expensive little packages have been arriving, this week:-
Stainless spokes and nipples.
Pattern kicksart lever.
APE Barrel studs.
PMC Mag drain plug.
Debben Heavy duty clutch plates.
Debben Gearbox bearings.
Various genuine bearings, bolts, gaskets,seals + springs
Corrosion on the gear selector shaft and kickstart shaft was sorted by a trip through the blaster and a couple of coats of bright zinc spray.
Cleaning the threads out is a slow job - but has its rewards, finding part of a bung could have been a headache later in the build - removal at this stage is so much easier.
Trial assembly showed no issues, gear assembly ran smoothly with the new bearings.
The corrosion has claimed another victim, no 3 cylinder liner is scrap, pitting is over 3mm deep in places - another liner is needed.
Webike supply replacement liners - JB 130-99-018 - Cheapish too! 11,700yen - delivered.
Still undecided on the front brakes, could do with an upgrade - but can't decide on which way to go.
Such fun
Time is a precious thing at the moment so progress continues to be slow.
Lots of expensive little packages have been arriving, this week:-
Stainless spokes and nipples.
Pattern kicksart lever.
APE Barrel studs.
PMC Mag drain plug.
Debben Heavy duty clutch plates.
Debben Gearbox bearings.
Various genuine bearings, bolts, gaskets,seals + springs
Corrosion on the gear selector shaft and kickstart shaft was sorted by a trip through the blaster and a couple of coats of bright zinc spray.
Cleaning the threads out is a slow job - but has its rewards, finding part of a bung could have been a headache later in the build - removal at this stage is so much easier.
Trial assembly showed no issues, gear assembly ran smoothly with the new bearings.
The corrosion has claimed another victim, no 3 cylinder liner is scrap, pitting is over 3mm deep in places - another liner is needed.
Webike supply replacement liners - JB 130-99-018 - Cheapish too! 11,700yen - delivered.
Still undecided on the front brakes, could do with an upgrade - but can't decide on which way to go.
Such fun
October week 2 update.
Mikey continues to demonstrate his talent - Polishing doesn't come better than this.
I find building forks good fun, I've used progressive springs and 15wt oil, genuine seals, pattern washers and circlips.
I did get some pattern dust covers - but I have junked them for genuine.
Genuine Studs, drain washers & sealing washers.
Hubs came back from Steve Smethurst, ceramic cleaning looks great - sisal polishing where I didn't ask for it - does not!!
Test laced the front hub, S/Steel spokes fit the hub really well.
Central-Wheel sent two extra spokes per side - not sure why - maybe just in case one breaks!!!
Picked up the head from the machine shop yesterday - with a busy weekend coming up I doubt I'll get a chance to play till next week
Frame at the powder coaters, pistons on order, cylinder liner on it's way from Japan.. Happy days
Mikey continues to demonstrate his talent - Polishing doesn't come better than this.
I find building forks good fun, I've used progressive springs and 15wt oil, genuine seals, pattern washers and circlips.
I did get some pattern dust covers - but I have junked them for genuine.
Genuine Studs, drain washers & sealing washers.
Hubs came back from Steve Smethurst, ceramic cleaning looks great - sisal polishing where I didn't ask for it - does not!!
Test laced the front hub, S/Steel spokes fit the hub really well.
Central-Wheel sent two extra spokes per side - not sure why - maybe just in case one breaks!!!
Picked up the head from the machine shop yesterday - with a busy weekend coming up I doubt I'll get a chance to play till next week
Frame at the powder coaters, pistons on order, cylinder liner on it's way from Japan.. Happy days
October Week 3 Update
Webike parcel arrived so cylinder liner has gone off to the machine shop for installing and honing.
Another Z Power parcel, 66.5mm piston kit plus another head gasket and a set of genuine stem seals.
Last of the parcels from CMS arrived, I find them useful for some of the genuine NOS original parts.
First of the super bright Zinc plating came back from Mikey.
Picked up the powder coating, have left the big bits wrapped, jobs for another day.
Engine assembly went well, new clutch plates, springs etc finished off the bottom end mechanicals.
Sticking with points on this bike, the budget won't stretch to Dyna Ignition. Mirror polish clutch cover looks the dogs danglies!
It was quiet at work yesterday so I've started to put the head together, not too pleased with the hot bath the machine shop used to raise the temperature to get the valve guides out (didn't use a torch so as not to wreck the head finish!), the fluid left a brown residue behind which has proven to be a pain to remove.
Sadly the plug threads had to have TimeSerts fitted, the corrosion had eaten the threads away too much to risk.
Genuine new valves, springs, stem seals, spring washers, buckets are in, Stainless Steel exhaust studs look good.
Webike parcel arrived so cylinder liner has gone off to the machine shop for installing and honing.
Another Z Power parcel, 66.5mm piston kit plus another head gasket and a set of genuine stem seals.
Last of the parcels from CMS arrived, I find them useful for some of the genuine NOS original parts.
First of the super bright Zinc plating came back from Mikey.
Picked up the powder coating, have left the big bits wrapped, jobs for another day.
Engine assembly went well, new clutch plates, springs etc finished off the bottom end mechanicals.
Sticking with points on this bike, the budget won't stretch to Dyna Ignition. Mirror polish clutch cover looks the dogs danglies!
It was quiet at work yesterday so I've started to put the head together, not too pleased with the hot bath the machine shop used to raise the temperature to get the valve guides out (didn't use a torch so as not to wreck the head finish!), the fluid left a brown residue behind which has proven to be a pain to remove.
Sadly the plug threads had to have TimeSerts fitted, the corrosion had eaten the threads away too much to risk.
Genuine new valves, springs, stem seals, spring washers, buckets are in, Stainless Steel exhaust studs look good.
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