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Z650 into 810 project

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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Crofty
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#76 PostAuthor: Crofty » Thu Feb 16, 2012 11:23 am

A couple of things got done this week. I have mounted the front forks after having some spacers machined up to centralise the wheel, the yoke has been powder coated (so i could fit and forget the lower taper bearing and seal).
I also had two spacers made up for the rear swingarm so it don't move side to side and the rear wheel axle from the 1100 Zephyr has been shortened and rethreaded to fit the 550 Zephyr swingarm.
Ray Debben has contacted me to say the head is done and will be on its way back soon!

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Front forks in.

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Side view, must get a rear tyre.

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One of the swingarm spacers just visible.

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j.b
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#77 PostAuthor: j.b » Sat Feb 18, 2012 8:41 am

coming together very nice crofty.....carnt wait to see the reworked head :D
straightening the curves and flattening the hills

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#78 PostAuthor: Crofty » Sat Feb 18, 2012 7:00 pm

Cyl head pics will be next week j.b.
I have got the rear wheel close to centre, now need to have a spacer made up. Oh for a lathe. Also got a zephyr rear caliper, hanger and torque arm to play around with.
Can you remember the choices of calipers that will bolt straight to the fork bottoms j.b (obviously ZX9R c1 models will)?
Will any brembos fit?
Does anyone know how far the discs are apart on a ZX9R C1?

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#79 PostAuthor: j.b » Sat Feb 18, 2012 10:09 pm

i'm using suzuki srad calipers on mine jim, bolt straight on with 300mm diameter discs.
not sure about any brembos, but would be interesting to find out if any have the same 90mm mount hole spacing :idea:
straightening the curves and flattening the hills

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#80 PostAuthor: Crofty » Wed Feb 22, 2012 2:34 pm

Recieved head back from Debbens today, it looks good. New valves, APE springs, guides, seals and buckets. Ready to fit, once I have painted it.
Here are a couple of pictures
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Has anyone got any old front sprockets for z650 with one or two more teeth than std? Need to be checking what will fit in there, smaller back wheel is going to lower gearing, so will have to up front to keep up with zephyr larger rear sprocket which also lowers gearing.

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GUYZED
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#81 PostAuthor: GUYZED » Thu Feb 23, 2012 2:49 am

Jim...i might have a old front spocket off my Z650 thats one or two teeth bigger...have to go hunting in the garage...i'm sure it's in there somewhere...i'll let you know.
OLD ZED'S NEVER DIE THEY JUST GO FASTER...
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#82 PostAuthor: tlc » Thu Feb 23, 2012 7:11 am

Crofty wrote:Does anyone know how far the discs are apart on a ZX9R C1?


I used the diagrams contained within those awful chinese replacement discs you see on ebay. Neverland is the name they go by.

Using those I was able to find out that `98 model Blackbird discs fit `96 CBR600 and have the correct offset to fit the ZRX caliper spacing and are 310mm. I did also double check by measuring physically in various bike shops.
Asphalt Cowboy

Phil Churchett award winner 2015

Crofty
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#83 PostAuthor: Crofty » Thu Feb 23, 2012 9:27 am

Thanks lads. Will investigate the disc scenario, could always do adapters, but prefer the std look if at all possible. Crofty

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#84 PostAuthor: GUYZED » Sat Feb 25, 2012 1:33 am

Jim...had a look the the garage and found a 16 tooth front spoc...i think thats the biggest you can go...pm me your address and i'll get in the post to you.
OLD ZED'S NEVER DIE THEY JUST GO FASTER...

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#85 PostAuthor: Baldylocks » Mon Feb 27, 2012 11:09 pm

Crofty, you can go to a 17 tooth sprocket if you need to, that is the largest you can go tho as any bigger and it will hit the clutch push rod, you could "possibly" go bigger if you use the later Gpz/Zephyr clutch housing ...
Bugger ! whose Idea was that!

'78 Z1r '79 z650/1100 '77 Seeley H**** 750 GPz1100 B2 '86 GSXR750R Ltd '97 KTM620 '76 S3a 400

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#86 PostAuthor: Crofty » Tue Feb 28, 2012 1:26 pm

Thanks bl, the 750 clutch route had crossed my mind, think i will go 1 extra at front and go down about 3 or 4 rear, should be possible. baz at Blue Haze has my rear carrier and caliper hanger sleeve. Taking 6 mm from under sprocket, chain will miss tyre, but will be needing offset front sprocket when time comes. jim

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#87 PostAuthor: Crofty » Wed Mar 14, 2012 9:14 pm

Have wheels centralised now 14/03/12. Took a couple of go's, Baz at Blue Haze taking a bit off each time. Today I actually took the whole bike over there and used his laser set up to get it bang on
Looks like I need a 9 or 10mm offset front sprocket. I used a slightly offset from from j.b with a spacer under. Scrounged a buggered chain from Transit Motorcycles in York, which helped greatly in judging alignment of chain and checking if it cleared frame and tyre. Just got to decide std gearing or one extra. Think I will go up one, due to slightly smaller wheels, I know I can get rear sprocket with more teeth if this is too tall.

I have found out I will need ZX9R rotors which will bolt to the Zephyr wheels, correct offset and 10mm smaller diameter, so will clear the calipers.

Image

Image

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#88 PostAuthor: Crofty » Mon Apr 02, 2012 5:48 pm

I have been looking for an oil cooler for months on ebay, but most looked squashed, filthy or corroded. Finally spotted one last week, at 20 pounds the price was good and had the oil lines. it turned up this morning, its sound, clean and the two oil pipes even released without any effort. It was off a GT750 shaft drive P7 model, smallish, but that way will stay out of the way.
Spent the afternoon making some mounts and welding them to the frame, careful to check lower yoke misses when on full lock and there is enough room when hard on the brakes.
It is also important that it does not sit directly in line with the top part of the head as it can lead to the exhaust cam area getting too hot.

Image

The frame is now ready to have all the bits taken off and sent for media blasting and powdercoating.
What I envisaged as a small job ended up with steering lock removed, rear footrest brackets removed and different style ones made and welded on, frame bracing, oil cooler mounts welded on, new lockstop for ZX9R yokes, adapting jb's B1 rear section so as to accept tail cowling, moving the seat brackets, altering the angle of the seat stay slide and moving the top rear brake master cylinder mount back a few mm to accept the brembo one.

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#89 PostAuthor: Royalratch » Sun Apr 08, 2012 2:31 pm

Nice stuff Crofty. Big progress - not far from bolting it up now.

I'm really into ultra stripped down but for the case for an oil cooler is strong. Perhaps mounted under the seat so it's invisible.

Did you have any other mount options?

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#90 PostAuthor: Crofty » Sun Apr 08, 2012 2:51 pm

I could'nt see any other alternative Ratch. There were some period racers that had them mounted above the rear seat cowl on 900/1000s , but I prefer them at the front like 99.99% do, Kawasaki mount the stock ones there. If you have it anywhere behind the motor its going to be getting sheltered by the head/barrels and getting warmer air.
I have just removed all bits off frame and cleaned the welds up with sander and a file in readiness for getting it blacked. Crofty


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