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.

B2 revisited rebuild

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

Message
Author
pluto
100Club
100Club
Posts: 185
Joined: 12th Mar 2012
Location: Bath

B2 revisited rebuild

#1 PostAuthor: pluto » Mon May 07, 2012 6:59 pm

Image
This is what I started with, see B2 revisited in 'New Here?'.
All looked ok on the surface, lick of paint and back on the road. It was not to be, further examination and strip down revealed some horrific bodgery and lack of use of a torque wrench resulting in thread carnage everywhere.
Image
What we have here are the inlet cam caps which have been snapped in half and re-welded, there's also a 13mm bolt holding no4 cap on. All the ends of the valves are mushroomed and wouldn't come out of the guides. The welding put everything out of line and the cam bearings were demolished. Time to find a new head.
Image
Frame hadn't fared too well either. stripping paint revealed rust on rh bottom frame rail which quickly turned into a hole when prodded. This was patched in with similar size tubing and welded up. Original tank was beyond repair so this is a replacement, paint removed and in very good condition
Image
Frame welded up and painted, Koni shocks stripped and rebuilt, original metmachex swing arm back on, new spindle as threads stripped and then cut off with no room for the nut to wind on more than a couple of threads. The bike is hanging from the rafters in my building company store - could do with a tidy up.
Image
Found a NOS headlamp fairing for the bargin price of £50.00 came with an undamaged tail piece for a further £10.00. Forks rebuilt with new seals and Hagon springs
Image
Another piece of luck, one 18 inch 1100R wheel, this I have to admit cost a little more than a tenner but I had one on the bike previously and it does help the handling. The mudguard is a Meadspeed RG500 guard that I had to chop up and rebuild to make fit properly.
Image
A rolling chassis takes pride of place in the lounge. I don't know how I got away with it but my wife and daughters are quite happy with the new ornament.

User avatar
Richard L
100Club
100Club
Posts: 177
Joined: 19th Jan 2012
Location: Heidelberg, Germany

#2 PostAuthor: Richard L » Mon May 07, 2012 7:16 pm

About time too, I have been waiting for this to start. I must say I am amazed you got anything done in that garage what a tip !! But seriously I admire your perserverence I think I would have thrown it all in the garden and set fire to it.
I also feel a bit guilty being the one who spotted this for sale on fleabay in the first place. Keep it coming but can't you get a proper camera !!
All the best
Big Brother

User avatar
jules
100Club
100Club
Posts: 368
Joined: 8th Feb 2010
Location: south devon

#3 PostAuthor: jules » Mon May 07, 2012 7:41 pm

AAAAAhhhh,at last,been waiting along time to see this!! Will this turn into a nice little mine is better than yours post!! Can't be as bad as what mine is turning into!! Good luck with it,look forward to seeing the progress.
P.U.M
'78 z1000a2,'83 1000r,'76 Z900a4,07 gsxr1000k6,'01 bj250,'03 husky 450,'83 Z1170r Lawson.

User avatar
Z1parR
Hardcore
Hardcore
Posts: 4901
Joined: 11th Oct 2009
Location: Chorley Lancs

#4 PostAuthor: Z1parR » Mon May 07, 2012 8:04 pm

Nice one pluto its all taking a shape now , and you know that you havn't got away with it :lol:
0172 . Geoff Parr

User avatar
mutz-nutz
100Club
100Club
Posts: 234
Joined: 18th Apr 2012
Location: northumberland (uk)

#5 PostAuthor: mutz-nutz » Tue May 08, 2012 11:04 am

looks like this might be a good build keep pics coming m8 :D
turn full circle and bite ya own arse !!

pluto
100Club
100Club
Posts: 185
Joined: 12th Mar 2012
Location: Bath

#6 PostAuthor: pluto » Tue May 08, 2012 7:00 pm

Cheers for the responses, the bike is nearly back together - a lot of the work on the engine was done in my shed at night during this winter and my phone didn't have a flash on it so photos of that bit of the resto are limited. I will post what I've got in the next few days.
Dave

User avatar
paul doran
Area Rep.
Area Rep.
Posts: 15910
Joined: 24th Sep 2004
Location: near Dublin Ireland

#7 PostAuthor: paul doran » Tue May 08, 2012 7:18 pm

beggining to take shape good for You
way too many Zeds

pluto
100Club
100Club
Posts: 185
Joined: 12th Mar 2012
Location: Bath

#8 PostAuthor: pluto » Thu May 17, 2012 8:04 pm

Image
Next installment; time to rebuild the engine in my shed. I have found a replacement engine cheap with a good cylinder head. I reground all the valves, had it refaced and popped in some new stem seals and helicoiled a few dodgy threads.
The engine had been bored out in the nineties to 1170 and the piston tops machined to reduce compression, the bores were ok so I had them honed and fitted some new rings. I had the top of the barrels refaced at the same time.
I pulled the cases apart to check all was ok and replaced the gearbox bearings.
Reassembly took a while due to work getting in the way, but went quite smoothly.
Thanks for the forum tip on compressing the rings with drain pipe, I used 4 inch soil pipe that I had in abundance and chopped out a 1/4 of the circumference - it worked a treat.
Engine sprayed with PJ1 and two pack for the cases.
Last job was bolting on the gearbox sprocket, trouble was I hadn't realised the previous owner had snapped off the retaining bolt in the output shaft and then held the sprocket on by 4 threads. This required drilling out a bolt to catch the remaining threads and carefully drilling out the broken bolt. It went slowly but worked ok, one slip and I would have had to pull the motor apart to replace the shaft.


Image
Engine back together and in the frame


Image
Oil cooler I fitted in the nineties repainted and back on its original bracket


Image
Carbs are 1100 shaft 34mm mikunis that I borrowed off my other Gpz, I rebuilt them with new pilots and float valves, I may refit the injection at a later date when its all running or get some different carbs

Remaining jobs were repair and retape the wiring loom, and fit the body work
The replacement tank needed some repair work around the badge mounts as I wanted the original badges, I got the tank badges from zpower but couldn't get genuine side panel badges anywhere, I eventually found some on ebay in the US of A and had them posted over.The paintwork was finished back in January and fitted to the bike still in the lounge to spur me on.

Image

Image
My brother kindly donated the screen, a quality repro from Germany

I cleaned up and fitted the original sebring pipe, filled it with oil, charged up the battery and pressed the starter, 3 or 4 turns later it fired up and I went round the estate to celebrate, my first ride on the bike in 20 years!

Image
Apart from a change of colour I have built the bike as close as possible to how it was when I used to own it. Many thanks Richard for all the bits that came from your parts stash to help finish it off. And no - it's not allowed back in the lounge.

User avatar
steve bowdler
Area Rep.
Area Rep.
Posts: 1793
Joined: 20th Apr 2005
Location: swansea s.wales

#9 PostAuthor: steve bowdler » Thu May 17, 2012 8:14 pm

looks super , you have done a grand job :D :D

User avatar
knut
100Club
100Club
Posts: 427
Joined: 24th Jun 2007
Location: cork,Ireland

#10 PostAuthor: knut » Thu May 17, 2012 8:40 pm

looks superb well done :up
what,s there to say except we,re all mad on here.

shrekward
Hardcore
Hardcore
Posts: 1264
Joined: 20th Feb 2008
Location: peterborough

#11 PostAuthor: shrekward » Thu May 17, 2012 8:41 pm

I think that that looks wonderful!

User avatar
Pigford
Hardcore
Hardcore
Posts: 13314
Joined: 2nd Jan 2006
Location: North Dorset

#12 PostAuthor: Pigford » Thu May 17, 2012 9:07 pm

Well Lush machine :twisted:
And on the 7th day... Zeds were created!

User avatar
london calling
Hardcore
Hardcore
Posts: 3992
Joined: 16th Apr 2004
Location: Loughborough, East Midlands

#13 PostAuthor: london calling » Fri May 18, 2012 4:16 am

Nice one Pluto :wink:
Jack

User avatar
Ginger Bear
Hardcore
Hardcore
Posts: 6850
Joined: 16th Dec 2008
Location: In the Dark.
Contact:

#14 PostAuthor: Ginger Bear » Fri May 18, 2012 6:29 am

That looks a beauty, be good to see it 'in the flesh'. :up
Image

# 104

Phil Churchett Award Winner 2011 & 2016 :D
Buzzworkz Best Modified Zed 2016

User avatar
Richard L
100Club
100Club
Posts: 177
Joined: 19th Jan 2012
Location: Heidelberg, Germany

#15 PostAuthor: Richard L » Fri May 18, 2012 7:38 am

Excellent job looks really good. Has it passed it's mot yet so you can take it for a proper blast ? I am not sure I would put the injection back on , mine is driving me round the bend at the moment maybe I can rip it off and send it to you !!
Richard


Return to “Projects”

Who is online

Users browsing this forum: No registered users and 11 guests