Z1OwnersClub GB

I thought it time I made my first post about my Z1000 project. I have been fantasising about building my ultimate Zed for may years since I first laid eyes on one when I was about 16. I've built many a special including a GS1000, Duke 851, ZXR750, super Tenere, and ZRX11 to name a few. Never been able to get my hands on a Zed until now as I have been living on the other side of the world for the past 20 years where Zeds are rare as rocking horse teeth!

The aim is to create a masterpiece of fusion with old style Zed looks and original features, but with bang up to date running gear and a minimalist look. My simple rule is nothing goes back on unless I am 100% happy with it

So here's what I bought as a starting point:
[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/PICT2247_zps347a89d4.jpg[/img][/img]
[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/PICT2232_zps586ad962.jpg[/img][/img]

Sorry for the poor quality pics, but these were the photos I bought the bike on and were taken by the seller.

Always underrated the Z1000B series. Strangely enuff, I'm picking a project LTD up soon.... just couldn't help myself


So, give us a few hints on the PLAN

First thing I did when I got the bike back to my lair was to fully strip it all down and assess what I was dealing with.
[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-03120357_zps1220bd63.jpg[/img][/img]
[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-03120243_zpse601f5e0.jpg[/img][/img]
[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-03131523_zpsa571b630.jpg[/img][/img]
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Things I already knew at this stage were that the frame was in very good nick and looks straight, the cylinder head has some fin damage and that the engine will only partially turn over on the kick-start until it locks up

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-05174144_zps02d4c580.jpg[/img][/img]

All looks ok so far...

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-05165353_zpsd702bb2b.jpg[/img][/img]

Bit of wear on cams but what do you expect?

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-05174219_zpse592a187.jpg[/img][/img]

Cracks in combustion chamber between plug holes and valve seats, cracked fins and exhaust stud bosses cracked. May look for another head?

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-09181339_zpsa2a32d2f.jpg[/img][/img]

Bonus is that it has an 1105 Wiseco kit fitted. Bad news is that on pot 4 the top ring has broken up and headed north and modified the combustion chamber

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-09181254_zps8c468cc7.jpg[/img][/img]

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/2014-05-09181417_zps22b63b6d.jpg[/img][/img]

Its an old Wiseco kit 4052 forged piston which i think may be hard to replace as a single item. The current 4052 kit I think is a more modern piston design, so buying a new single replacement may not be possible??

Other issues are:
3 bent valves (that will be why it wouldn't turn over-timing out by a mile)
Clutch basket springs broken up
Con rod 3 looks scorched as though it has been running hot
Cam chain and sprockets look to be fairly worn

Otherwise mostly ok. Gearbox looks like new with no rounded dogs or worn teeth, sprocket cover cracked inside. Looks like I will be looking at a big spend on the motor, but that's what its all about. Now where's that APE catalogue

So, give us a few hints on the PLAN Twisted Evil

Jeez Pigford you don't hang around!

Rough plan is: XJR13 rear swingarm, either Gazi or YSS shocks, R1 5VY rear wheel, and caliper, R1 5VY complete USD front end, Harris pipe or preferably stainless copy, flatsides, pod filters, cams, big bore, gas flow, palin ally engine with polished bits. Lots more to come, but don't expect it to be done too soon as I'm in no rush to make the perfect bike

1st things 1st, clean, clean, clean, vapour blast. Good job that work has a degreaser and a few blast cabinets. Many an hour spent after work cleaning and blasting all the engine casings. Here's some of them:

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/IMG_0025_zps948dc260.jpg[/img][/img]

Top crank case has damage around starter motor skirt. Nowt to be done but be off with it:

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/IMG_0049_zps9fd0636b.jpg[/img][/img]
[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/IMG_0051_zps91652a2f.jpg[/img][/img]
[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/IMG_0050_zpsaa419cb6.jpg[/img][/img]

May get a piece welded back in or may just leave it as is??

Got the XJR13 swingarm from DK and machined 12.5mm off each side of the pivot tube to get it in between the frame rails. Plan is to use the original 16mm OD Zed spindle and use bearings to fit the 33mm ID of the swingarm.

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/IMG_0009_zps27a7c828.jpg[/img][/img]

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/image2_zpsf0332918.jpg[/img][/img]

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/image1_zpsd69637a2.jpg[/img][/img]

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/image3_zps81af41d2.jpg[/img][/img]

Frame has had numerous brackets removed and sanded those parts of the frame. Wheels and forks are left over from my ZRX11 which I changed for ZX12R items.

Forks will not stay so will be up for grabs when I get an R1 front end. Rear wheel needs to go too.

Swingarm has no bushes in it yet and rear wheel bearings are too large, hence the wonky rear end

Pigford wrote:Always underrated the Z1000B series. Strangely enuff, I'm picking a project LTD up soon.... just couldn't help myself


So, give us a few hints on the PLAN

Is'nt that an a1/2, rear footrest hangers are different on b models, please correct me if I am being a t**t, worse still am I becoming a rivet counter.

Must admit, that's what I thought...looks like an 'A' frame to me.

and.....

"but don't expect it to be done too soon as I'm in no rush to make the perfect bike"

if this is hanging about...I shudder to imaging what you work like if you want to hurry up...all this in one day!!!!

kev edwards wrote:

Pigford wrote:Always underrated the Z1000B series. Strangely enuff, I'm picking a project LTD up soon.... just couldn't help myself


So, give us a few hints on the PLAN

Is'nt that an a1/2, rear footrest hangers are different on b models, please correct me if I am being a t**t, worse still am I becoming a rivet counter.

Piggy's been on the cider!!!

if this is hanging about...I shudder to imaging what you work like if you want to hurry up...all this in one day!!!!

Certainly not one days work, just playing catchup on posting

Is'nt that an a1/2, rear footrest hangers are different on b models, please correct me if I am being a t**t, worse still am I becoming a rivet counter.

I'm no rivet counter but I believe it to be an A2. It looks like a Zed and thats all that matters to me

Got R1 rear wheel off ebay fitted with 200 section slick, it was a punt but fits with only0.43mm off centreline and nicely in centre of swingarm.

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/IMG_0053_zpsccf221e6.jpg[/img][/img]

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/IMG_0054_zps37cb91ed.jpg[/img][/img]

[img][img]http://i28.photobucket.com/albums/c207/mikeandbron2012/image11_zps7a94a953.jpg[/img][/img]

Now just to make the chain fit!

Zomerset Zed wrote:It looks like a Zed and thats all that matters to me

Well said that man!
This is a great project thread, 180/190 rear tyre with 530 chain
will be just enough clearance for the frame, (in case you
didn't already know). Looking forward to more updates of
your perfect Zed

PJ wrote:

kev edwards wrote:

Pigford wrote:Always underrated the Z1000B series. Strangely enuff, I'm picking a project LTD up soon.... just couldn't help myself
So, give us a few hints on the PLAN

Is'nt that an a1/2, rear footrest hangers are different on b models, please correct me if I am being a t**t, worse still am I becoming a rivet counter.

Piggy's been on the cider!!!

My bad - didn't notice the rear footrest hangers - only saw the seat

Pigford wrote:

PJ wrote:

kev edwards wrote:

Pigford wrote:Always underrated the Z1000B series. Strangely enuff, I'm picking a project LTD up soon.... just couldn't help myself
So, give us a few hints on the PLAN

Is'nt that an a1/2, rear footrest hangers are different on b models, please correct me if I am being a t**t, worse still am I becoming a rivet counter.

Piggy's been on the cider!!!

My bad - didn't notice the rear footrest hangers - only saw the seat

If it's any consolation I did not notice the seat, noticed the ltd mudguard though, will be watching this one.

A note on chain clearance - a 630 will work with a 180 tyre + 5/8" offset drive sprox - bit close but my Z1000 has run one for 10yrs no problems except it can skim a bit of rubber off the tyre edge