Z650/1100

[Baldylocks]

Hello all, only posted on other peoples threads before but have been a Z fan for a verrrry long time, here is my Z650 that I have owned for over 30 years..It has been modified in various guises since I got it the last incarnation it had an 810 motor but I lost interest and left it parked up for over 10 years, last year I was made redundant and to keep myself amused/busy I bid on a zx1100 motor on flea bay and won it so here we go........

This is what I started with to create my 650/1100

Not posted a photo before so this might not work!



Image014a (2) by Baldylocks2011, on Flickr

[Baldylocks]

Ok! now I have sussed how to get the pictures up I will post a few more tomorrow!

[PJ]

Wow Baldylocks that is going to be one hell off a beast,

More pics and writing please

[Baldylocks]

PJ thanks for the comment, blame must lie with J.Wilson for proving that it was possible! with his epic thread , and also with Nosher903 for getting me to Join the Z1OC and getting me to join this forum too... otherwise it would probably have still sat at the back of the workshop for another few years.

cheers

[Ginger Bear]

Looking forward to watching this unfold.

[Pigford]

Mean Machine

[Baldylocks]

Thanks chaps, as promised here are some more pics as I know you like piccies once it is finished and in one piece I intend to get it painted back to original z650 B1 Candy red, also my aim has always been to use only Kawasaki parts on it, hence the ZXR750 Forks and Wheels modified Zephyr 750 Swing arm etc

Here is the strip down

[img][img]http://farm7.static.flickr.com/6040/6273250485_b6380f39e0.jpg[/img]
Image035 by Baldylocks2011, on Flick[/img]

Ready to pull the 810 motor

[img][img]http://farm7.static.flickr.com/6102/6273252797_1f506a7a6c.jpg[/img]
Image038 by Baldylocks2011, on Flickr[/img]

And using the easiest option to get it out put it on it's side and lift the frame off

[img][img]http://farm7.static.flickr.com/6091/6273252287_999803f90c.jpg[/img]
Image039 by Baldylocks2011, on Flickr[/img]

Then the moment of truth well not really as I had J.Wilsons thread that confirmed it would fit with a few subtle modifications I just wanted to confirm to myself this was the case......

[img][img]http://farm7.static.flickr.com/6212/6273778698_76b8ce7a61.jpg[/img]
Image040 by Baldylocks2011, on Flickr[/img]

So it was out with the Grinder and off came the front lower 650 engine mounts and hey presto it's in I made some MDF patterns for the Engine mounts

[img][img]http://farm7.static.flickr.com/6109/6273259175_34dd33c81e.jpg[/img]
Image054 by Baldylocks2011, on Flickr[/img]


More to follow

cheers for now[/img]

[j.wilson]

Excellent thread- I feel honoured to be mentioned.

Note that you need to fit the engine as low as possible so you can get the cam cover off without dropping the engine.

Also, go for as big a front sprocket as possible as it will reduce the chain rattling on the swing arm.

[Baldylocks]

Guru Wilson! I am honoured that you would post on my thread! Really liking the return of your thread, oh and congratulations on getting married. (also I based my engine mounting as best I could on your setup so I will have to drop the front mounts out to remove the cam cover but that was because I wanted the sprocket drive shaft to be in the same plane as the swingarm Pivot and the engine to sit as level as possible cheers)

Ok latest update is where I am now.

I tacked in the new support tube for the lower front engine mount


Image011a by Baldylocks2011, on Flickr

Then tacked the mounts themselves, I actually lined them up and cut slots in the tube before tacking them


Image014 by Baldylocks2011, on Flickr

then out with the motor and welded them up fully this was a pain as my MiG welder decided it didn't want to play and I had to resort to Arc welding it all in....not my preference but it actually looked "Factory" !!! compared to my 1100B2!

I forgot to take pictures before I gave it a coat of paint...Doh but I was quite excited at this stage!


Image019 by Baldylocks2011, on Flickr


Image017 by Baldylocks2011, on Flickr

Then onto bolting it all back together...


Image016 by Baldylocks2011, on Flickr



[/img]

and that is where I am upto now, a mate is machining me a new top yoke after I gave him a lump of Billet so once that is done I can get it back on its wheels, then I will borrow the Kerker that is on my B2 and also the shocks, in the meantime I have to work out how to wire it up and also get the following:-

Igniter for a zx1100 A1 motor
new inlet rubbers for the 33mm Mikunis
5/8ths offset Sprocket
Brake lines front and back
and a few other bits and pieces

Anyhow thanks for looking hopefully I'll be back with an update in a few weeks.

Cheers

[Padders]

Excellent work I look forward to the next installment.

[j.wilson]

Great work Baldy.
*sigh* I wish I could weld. Never trust anything I've welded.

I welded my foot rests temporarily, to position them.

I was trying out the position and rested my feet on them- one just fell off!

It seems you put your engine where I put mine. It’s quite a bit more work to lower it further as that nearside front mount is on the frame already.

You have to do what I do to remove the cam cover- but I guess it’s no great ordeal.

This bike is going to be a cracker when it’s done.

The z650 is such a good handling chassis and with a 120hp motor it is light and powerful.

Modern tyres and brakes make the most of it.
The rest just comes down to style.

I don’t know how you could improve the basic recipe of this set-up.

[Ginger Bear]

Bloody not hanging around there. Great work so far.
Don't forget the club now run a shim swap for the 13mm shims, contact me when you're ready.

Biggest front sprocket you'll get on (sensibly) is a 19t 530 5/8" offset. I had one specially made by Talon, to fit my Unitrak motored 1170R running 17" wheels, but it made the bike really overgeared with a 42 (ish) tooth rear.
I ended up fitting an 18t, supplied 'off the shelf' by Debben.

If you want to try it, your welcome, probably need to fit something like a 45-46 tooth rear, but thad should lift the chain well clear of the swinger.

[Baldylocks]

Chaps, thanks for the words of encouragement and also to GB for the loan of the sprocket, I have to admit that this build has been going a few months (I wish I could work that fast!! ha ha!) you know how it is with these things, 2 steps forward one step back..........

J.Wilson don't feel too bad about your welding it only gets better with practice and I think your other skills (design and Electronics) more than make up for it.

When tacking the front tube on I must have had the frame on and off about 10 times or more from the tacks breaking as I caught the brackets on the engine ha ha! it nearly got pushed to the back of the Workshop at that stage!

I'll be back with an update as soon as I have the new top yoke , now to go study the wiring diags.......

thanks again

[Taffus]

Welding!!!
Been on a course at brooklands college for the last 4 weeks, 3 hours on a Wednesday.
Starting to get better at it. Teacher is excellent, welds a lot of ally for a living his work is fantastic!
Once you have the principles its just practise. The first weeks safety lecture was a real eye opener.

[j.wilson]

Will you have to countersink some of the cam cover bolts?
I seem to remember they foul on the bottom of the tank in one place on each side.

My favourite bit the loom.
I used VWP for the stuff and went for vinyl tube with adhesive lined sleeves at the ends.
It’s not so expensive to make on a standard bike, and I found it provides a good improvement in reliability. Of course the wires themselves don’t really wear out they get pinched chafed and work hardened- the biggest issue being corrosion at the ends.
Even if you don’t replace the loom -have a good look at the one you are putting back.