Z650 refresh...

[Big Fluff]

Dave - You don't need the extension, ditch it and give me a bell

[MDM]

After a long discussion with Mr W Barber esquire, I decided that a larger crankcase breather might be advantageous, so I tried the breather housing from an earlier Zed, much like the one on the S&S turbo Zed...

As you can see, despite both bikes using Rajay turbos, the breather won't fit on mine...

[Big Fluff]

Now that is very confusing

[MDM]

Indeed it is Mr Fluffington... I'm thinking that I'll still use if, by cutting a strip out of the middle and welding to top to what remains at the bottom, and thus still being able to fit in a couple of breathers...

[Big Fluff]

Aha... I know why now.
You're using Mr Turbo pipework and not ATP! The ATP (whilst far superior) sits higher allowing access to other components.

[MDM]

So, having finally got back into the Shed of Dread, and ignoring the carb issue hoping it'll go away, I started actually doing some stuff. Although, unsurprisingly, not much...
After taking off the temporarily bolted on headers, I took out the two remaining exhaust port studs, and fitted a new set. Ooh, a teeny tiny step forward! I also got a mate to spin up a set of spacers for the oil cooler that I'll be fitting, so I can get on and make the bracketry for that. But had to go back and check out that rear wheel spacing. With the spacers that my good mate Sam had made, I got the wheel centralised within a mill' or so. Which was fine, but as the pic below shows, it is scarily close to the left hand side of the swinging arm, and the chain run is going to be close to the left-hand shock too. Added to which, it's looking highly likely that the chain and rear frame down tube will want to be occupying the same space.

I'm now thinking of shifting it to the right by five or ten mm, and accept a slight misalignment of wheels...

[MDM]

While fiddling with my rear end (er...) I found a caliper hanger that matched the spindle diameter, but which needs some machining to make it the right thickness for what I'd discovered on the left hand side of the swinging arm. And I bolted on an SV650 caliper I hand hanging about.

I dunno if you can see here, but it's right for the offset of the disc (zero) but not for the 210mm diameter.

So, with some guesswork and a ruler waved in it's general direction, I reckon I need a disc of 230mm diameter. Either that, or get a new caliper hanger made, and I think that the disc is the easier option! So, anyone know of any online disc dimension lsitings? Some quick measurements show that the disc fitted to the Dymag is a six bolt fixing (so a three bolt one would also do the trick) of PCD 109mm, with the central hole being 99mm diameter.

[MDM]

Oh, and I was reminded about something that's been bugging me since I first built the bike with the 1100 motor - the shock alignment.
When the swinging arm was made by Martek, the shock mounts were wider apart than the standard mounts, so they're a bit 'splay-legged'...

So I'm thinking of doing something with the top shock mounts to bring it all into alignment. The shocks worked fine, but it was always something that bugged me, and ikt just wasn't right.

[MDM]

I'd initially thought that I'd use this hanger -

But as it has a rubber damper in it (dunno why, most don't seem to have it, I think this was from a ZXR750H1) it'd be a bit pants to machine, so maybe I'll go with this one instead -

I've marked it up with the changes that it'd need to work, although I'd still need to find a larger disc, as you can see here -

[Big Fluff]

Wahey... some progress Dave
Your problem of the bottom LH shock mount close to the sprocket carrier can easily be overcome by machining the head of the bolt and reversing it, like I did on my ELR project.
Just make sure that you go one size up and tap a new thread into the swingarm.

[sanderz]

So I'm thinking of doing something with the top shock mounts to bring it all into alignment. The shocks worked fine, but it was always something that bugged me, and it just wasn't right.

There were some 'shock extensions for sale recently on here (now sold tho') but take it you'll be going down that route.
http://www.z1ownersclub.co.uk/forum/vie ... hp?t=32020

Rear wheel looks to have 6 bolt fixing for the disc - not found any at 230mm with 6 bolt (zxr750 5 bolt at 230) but this fella maybe able to help -

http://www.ebay.co.uk/itm/YAMAHA-R1-R6- ... 2597e5f01e

Don't know if that's of any use - keep it going tho'

[MDM]

Thanks guys!
Will - that pic is slightly deceiving, the shock bolt is clear of the sprocket by a few mill', and below the chain run by a decent amount too, so there'll be stacks of room if I shift the rear wheel over by 5mm, which is the current plan! (mainly so that I can get chain clearance at the frame to be honest).
Sanderz - those shock extensions were similar to what I had in mind, except rather than be screw-on jobbies, I was thinking of cutting the standard shock mount thread off and using a sleeve over the rest of the mount, welded into place and shifting the threaded portion out by only 5mm or so. Doesn't need to be as much an offset as those in the link you posted seem to have
And regarding the rear disc, Yantosh has suggested getting a disc laser / waterjet cut, so I may go that way...

[chrisNI]

And regarding the rear disc, Yantosh has suggested getting a disc laser / waterjet cut, so I may go that way...

Dave Trade Direct or EBC will make custom discs - when I was doing my Z1000 I needed a back disc with a Zephyr 1100 stud pattern and a Zx7 diameter for some reason (bad planning I think...) , and as I recall Trade Direct made it, but I went to EBC for cuatom front discs later on.

[MDM]

Cheers Chris - what kind of price were the custom discs, if you don't mind me asking?

[MDM]

Old goldfish brain here got distracted again, while I was fannying around fitting the new exhaust studs into the head I had a look inside the headers... and noticed that the inside of the header pipes had some 'clag' (for want of a better word) inside. The headers weren't genuine Mr Turbo ones, as they didn't fit due to the fact that the GPz engine sits further back in the Z650 frame than it did in the 1100 frame, so I had Mickey Burke at Eyeball Engineering in Tamworth make me some new headers (and up-pipe) to suit...


Time to get the Dremel out...