Z1OwnersClub GB

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.

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.

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

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.

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

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.

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.

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

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.

Nice one pluto its all taking a shape now , and you know that you havn't got away with it

looks like this might be a good build keep pics coming m8

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

beggining to take shape good for You

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.



Engine back together and in the frame



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



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.




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!


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.

looks super , you have done a grand job

looks superb well done

I think that that looks wonderful!

Well Lush machine

Nice one Pluto

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

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