Hello Guest User,
Please feel free to have a look around the forum but be aware that as an unregistered guest you can't see all of it and you can't post.
To access these 'Registered Users Only' areas simply register and login.
Please feel free to have a look around the forum but be aware that as an unregistered guest you can't see all of it and you can't post.
To access these 'Registered Users Only' areas simply register and login.
new member with Z900 project
Moderators: KeithZ1R, chrisu, paul doran, Taffus
-
Royalratch
- 100Club
- Posts: 366
- Joined: 3rd Jul 2009
- Location: London
Big day today. got the rear end sorted and dropped off the chassis at Harris for welding and assorted mods.
Rear end first...
The rear end is a mix of Z1 sanctuary swingarm, 17" ZX9R wheel, brembo caliper, bespoke ISR disc and a sculpture caliper bracket originally intended for a GPZ900R. Getting this lot to fit was a bit of a challenge, not helped by sanctuary supplying a 20mm rear axle and a 17mm caliper hanger. The central bush on the caliper had to be removed (not easy as it was an interference fit) and new bushes and spacers made. The wheel also had to be machined as the RH seal housing stuck out too far. Luckily, there is plenty of excess metal and it only needed 2mm taking off. I also removed the studs from the sprocket carrier, got it machined down 6mm and have fitted a 530 sprocket with bolts rather than studs. I think it all looks rather good now. There is a 14mm hole in the caliper carrier which aligns perfectly with the 10mm holes in the disc. I'll put 2 10mm magnets in the disc holes and fit a speed sensor in the 14mm hole, which gives me a neat speedo reading without needing a cable and drive on the front wheel.
Harris will weld on the shock brackets and torque arm bracket. I may get the arm clear anodised as I don't want it to corrode and I have a polishing allergy.
Rear end first...
The rear end is a mix of Z1 sanctuary swingarm, 17" ZX9R wheel, brembo caliper, bespoke ISR disc and a sculpture caliper bracket originally intended for a GPZ900R. Getting this lot to fit was a bit of a challenge, not helped by sanctuary supplying a 20mm rear axle and a 17mm caliper hanger. The central bush on the caliper had to be removed (not easy as it was an interference fit) and new bushes and spacers made. The wheel also had to be machined as the RH seal housing stuck out too far. Luckily, there is plenty of excess metal and it only needed 2mm taking off. I also removed the studs from the sprocket carrier, got it machined down 6mm and have fitted a 530 sprocket with bolts rather than studs. I think it all looks rather good now. There is a 14mm hole in the caliper carrier which aligns perfectly with the 10mm holes in the disc. I'll put 2 10mm magnets in the disc holes and fit a speed sensor in the 14mm hole, which gives me a neat speedo reading without needing a cable and drive on the front wheel.
Harris will weld on the shock brackets and torque arm bracket. I may get the arm clear anodised as I don't want it to corrode and I have a polishing allergy.
...so I then dropped the frame, forks, yokes, arm, wheels and brakes and assorted other bits off at Harris with instructions to turn it into a rolling chassis. Had a tour round the workshop while I was there. It's full of lovely bikes and bits and the quality of what they do is very impressive. Also discovered that Lester Harris has a very clean original Z1. Lester was initially somewhat sceptical - I guess a punter turning up with a big box of bits doesn't always end well - but he was very impressed with the Sanctuary parts and he couldn't spot any obvious schoolboy errors.
In about 4 weeks or so I should have a complete rolling chassis with suspension and brakes. I can then start installing the engine, electrics and hydraulics. I'm going to use a motogadget m-unit to replace the fuse box and a small lithium ion battery.
Tank and tailpiece are due back from Flying Tiger next week so it's finally starting to come together. Building it is going to seem easy after the delights of sorting out the front and rear suspension and brakes.
In about 4 weeks or so I should have a complete rolling chassis with suspension and brakes. I can then start installing the engine, electrics and hydraulics. I'm going to use a motogadget m-unit to replace the fuse box and a small lithium ion battery.
Tank and tailpiece are due back from Flying Tiger next week so it's finally starting to come together. Building it is going to seem easy after the delights of sorting out the front and rear suspension and brakes.
-
Ginger Bear
- Hardcore
- Posts: 6850
- Joined: 16th Dec 2008
- Location: In the Dark.
- Contact:
Went to visit Harris today. The frame is off being stripped but they have finished the front end. They made new spacers and welded a socket into the end of the spindle so you can use an allen key to hold the spindle while the nut is tightened. The calipers now align properly and the wheel sits in the centre. The Ohlins fork bottoms are assymetric and the lovely Sanctuary caliper spacers had been badly machined, so it wasn't simple. The faces of the spacers weren't quite parallel but I had ordered extra-thick ones. Harris milled them down to the right thickness and made sure it all aligned. Harris can access all the Ohlins drawings but no drawings are available for the RWU forks. They've never been officially sold in Europe as far as I know, mine came from Japan.
For the first time I now have forks, wheels, discs, calipers, axle etc that all fit together and will actually function. The plan is to go back in a couple of weeks and they will have removed all the surplus brackets and installed the swingarm. We can then finalise the shock mounts, install the bracing kit and so on.
The photos show the forks sitting on the counter at Harris and the neat spindle welding. Still have to sort a mudguard. I want something simple and traditional, but plastic not metal. Any suggestions?
For the first time I now have forks, wheels, discs, calipers, axle etc that all fit together and will actually function. The plan is to go back in a couple of weeks and they will have removed all the surplus brackets and installed the swingarm. We can then finalise the shock mounts, install the bracing kit and so on.
The photos show the forks sitting on the counter at Harris and the neat spindle welding. Still have to sort a mudguard. I want something simple and traditional, but plastic not metal. Any suggestions?
-
davy thomson
- ZedHead
- Posts: 1000
- Joined: 24th Aug 2005
- Location: scotland [north]
Harris have now stripped the frame, removed the redundant brackets and fitted the swingarm. The arm was designed for a Z1, not a Z900, but it all fits. I have been lucky with the frame (and the engine but that's another matter) as the only damage is to the rear indicator brackets. There is no corrosion and all the threads are fine. The LH indicator bracket will need to be re-made as I plan to fit original style chrome indicators. I don't like small modern ones.
Lester Harris is doing all the work himself as the project has really appealed to him. The PMC stiffening kit was designed for a Z1 and the Z900 has thicker tubes, so it doesn't fit very well in some places. At least the kit gives a place to start and Lester will modify or fabricate tubes/plates as necessary. I am using Z1 side panels so the frame also needs new lugs for those.
The rear shocks have been a problem as Lester reckons that we need a length of about 300mm, which is short. Ohlins do a set for a CB1300 which are 310mm long so they should fit. Funnily enough the front forks were also intended for a CB1300. This gives wheel travel of 100mm, which is a bit short but fitting 17" wheels does involve some compromises. We are trying to keep the front sprocket, swingarm pivot and rear axle as aligned as possible. Lester is also using pictures from the sanctuary website to keep as close as possible to a sanctuary bike.
Lester Harris is doing all the work himself as the project has really appealed to him. The PMC stiffening kit was designed for a Z1 and the Z900 has thicker tubes, so it doesn't fit very well in some places. At least the kit gives a place to start and Lester will modify or fabricate tubes/plates as necessary. I am using Z1 side panels so the frame also needs new lugs for those.
The rear shocks have been a problem as Lester reckons that we need a length of about 300mm, which is short. Ohlins do a set for a CB1300 which are 310mm long so they should fit. Funnily enough the front forks were also intended for a CB1300. This gives wheel travel of 100mm, which is a bit short but fitting 17" wheels does involve some compromises. We are trying to keep the front sprocket, swingarm pivot and rear axle as aligned as possible. Lester is also using pictures from the sanctuary website to keep as close as possible to a sanctuary bike.
The plan is to use a Super B lithium battery, motogadget m-unit central 'brain', ZX9R starter relay and electrex reg/rectifier. This is all quite small and will fit behind the side panel, leaving the space below the panels nice and open. I'm going to design and build a new custom loom which will be much simpler than the original as so many of the functions are done by the m-unit. The only problem I can find is that the m-unit doesn't allow for a headlamp flasher so that will require an external relay.
I now know 100% that the front and rear suspension and brakes will fit an work. There are still some other problems to sort. The rear loop that supports the tail unit looks slightly bent and I need to work out a plan for the rear mudguard. I think I'll use a Zpower fender eliminator at the back and Lester has offered to remove the frame brackets and make a splash-guard for the front of the rear wheel. Lester is concerned that the new upper suspension mount is in an unbraced frame tube and wants to fit a support, which has to clear the seat lock but all the (current) problems are actually quite minor. Amazingly I don't seem to have dropped any major clangers so far.
It's all taking longer than I expected but I am delighted with the thought and enthusiasm that Harris have brought to the project. Lester's Z1 hasn't turned a wheel for about 8 years and he is wondering whether he should upgrade his. When I get it back from Harris I will have a rolling chassis into which I can instal the engine and electrics with the aim of being on the road by Christmas. Sourcing suitable modern instruments with all-electronic drive (no cables) is proving to be a major pain but I'll get there.
I now know 100% that the front and rear suspension and brakes will fit an work. There are still some other problems to sort. The rear loop that supports the tail unit looks slightly bent and I need to work out a plan for the rear mudguard. I think I'll use a Zpower fender eliminator at the back and Lester has offered to remove the frame brackets and make a splash-guard for the front of the rear wheel. Lester is concerned that the new upper suspension mount is in an unbraced frame tube and wants to fit a support, which has to clear the seat lock but all the (current) problems are actually quite minor. Amazingly I don't seem to have dropped any major clangers so far.
It's all taking longer than I expected but I am delighted with the thought and enthusiasm that Harris have brought to the project. Lester's Z1 hasn't turned a wheel for about 8 years and he is wondering whether he should upgrade his. When I get it back from Harris I will have a rolling chassis into which I can instal the engine and electrics with the aim of being on the road by Christmas. Sourcing suitable modern instruments with all-electronic drive (no cables) is proving to be a major pain but I'll get there.
Re: new member with Z900 project
LondonZ1 wrote:Hi, this is my first post. I have just bought a scruffy non-running Z900 which I intent to restore/upgrade and put back on the road. I will post a picture when/if I can work out how to do it. The bike is a 1976 Z900 A4 which has been imported from California. I bought it off ebay and it will need quite a lot of work. The bike is mostly complete but has non-standard exhaust, wheels and seat. The engine turns over with the kick start but the bike will need a complete rebuild. I thought it was reasonable value at £2000 but ask me again when I have bought all the bits I need!
http://www.ebay.co.uk/itm/270858228408
I have been spending more time than is healthy on the Japanese Sacntuary website. My initial plan was buy a complete sanctuary bike and import it to the UK. A Japanese colleague contacted sanctuary for me and was quoted €40,000. I didn't bother to ask about shipping.
Plan B is to buy a scruffy bike and do my own Sanctuary. I want the bike to look as standard as possible but with modern suspension, wheels, tyres and brakes. I will try and track down some RWU Ohlins forks and will source a new swingarm from Japan. I would appreciate some advice on rear tyre size. It seems that it will be much easier to accommodate a 160 than a 180. Any comments or suggestions would be appreciated.
Welcome to the forum/club. All you will need to know will be on here with lots of help and advice on the zed.
Who is online
Users browsing this forum: No registered users and 5 guests