new member with Z900 project

[LondonZ1]

The forks have arrived and amazingly it all seems to fit. I've bought a used CB1300 spindle which also fits (the forks were originally intended for a CB1300) but might be a little short. It's quite a simple design so I can easily get a longer one made. Next challenge is a to choose a suitable wheel with 320mm discs and calipers that all line up. Sculpture make caliper carriers for Brembos with 40mm hole spacing and it looks like some Ducati ones will fit. I am trying to make it all neat with as few spacers and bodges as possible. BTW I tracked down the brake splitter, it's from a ZXR750. The attention to detail on the yokes is amazing. The tapped holes on the front lower yoke are the right distance apart for the splitter and there is even a hole for an OE steering lock.

Am having problems getting a sculpture swingarm sorted so have resorted to buying a (cheap) used Z750 rear wheel (right rim width and disc diameter) so I can get all the dimensions right.

More bits due from Japan next week. I have been using Webike who have so far been excellent. Icing on the cake was the non-arrival of a VAT bill from HMG for the yokes. They arrived via Parcelforce who usually ask for VAT etc upfront before delivery.

[LondonZ1]

I am making progress but not always in the intended direction! Have managed to get the engine completely out. I've bought some used Z1000 Mk2 cases from the US for $105, which have come up looking like new after the attention of I Cleenz Macheenz, awful name but great service (www.icmhome.org.uk). This gives me an engine number and some spare cases for the frame work. The head is off being refurbished at BLR Engineering, where it is getting new guides, seats and general refurb. I can't get new rings for the MTC pistons so will buy some new ones from pitstop in the US. The barrels are in good condition and will just need honing for the new pistions. Crank has been welded in the past and I will send it off to get checked out. The plan is to powder coat the whole engine satin black and fit new CR Keihins and Dyna ignition. I'll keep the after market camshafts but I still have no idea who made them. Haven't decided what to do about the camchain but am tempted to fit a complete Sanctuary kit rather than use APE etc. The Sanctuary stuff is the same price and I am trying to keep it as close as possible to a Sanctuary/Sculpture bike. If you're interested, my inspiration is RCM 056 on the Sanctuary website.

On the front suspension, I am now 95% done. Ohlins forks, Brembo goldline calipers, custom 320mm ISR discs with special offset and NOS ZX9R C wheels. Still need to get some special spacers made but have been busy with engine. Also ISR discs won't be here for 8 weeks. Sorting out the dimensions for the front end while keeping sensible suspension geometry has been by far the trickiest part of the project so far.

Have bitten the bullet and ordered a Sculpture swingarm from Japan. This is due in June. Sculpture were being very anal about dimensions so I have ordered the shock mounts loose and will get them welded on in the UK. Sculpture are also supplying a caliper bracket for a Brembo caliper and 250mm ISR disc.

Other bits from Japan: K Factory hydraulic clutch conversion and Babyface rearsets. I'll post pictures if people are interested.

If there are no disasters, I will take the frame, forks, wheels and swingarm up to Metal Malarkey in June or July and get the frame braced and the swingarm and rear supension sorted. Malcolm can weld on the swingarm brackets and install the wider top shock mounts. That means I will have a rolling chassis and can start worrying about the electrics.

[Crofty]

Should be one hell of a bike when ts finished Keep at it.

[Ginger Bear]

Other bits from Japan: K Factory hydraulic clutch conversion and Babyface rearsets. I'll post pictures if people are interested.

Yes Pleaze................

[LondonZ1]

Have now received the custom discs from ISR, which fit perfectly on the NOS ZX9R wheels. The front are 320mm with a special offset to fit the forks. The rear is 250mm (larger than standard) just because I thought it suited the bike. I ordered them from HPS and was told it would take 8 weeks. They arrived three weeks later!

I have also posted a pic showing how the calipers mount to the forks using Sanctuary brackets. I have screwed up on the brakes. I bought some used Brembos from a Ducati only to find that Brembo don't sell seal kits. Bummer! Will have to either pay Brembo to refurbish them or buy new ones.

Other bits that have arrived are the K Factory hydraulic clutch and the Braking clutch and brake master cylinder. The crank is away being checked out by Chris Applebee and the head is getting new seats, guides and a helicoil from BLR Engineering. With luck I will be able to get the enigne off to the Triple S for powder coating in about 2 weeks.

[Baldylocks]

For seal kits for your Brembo's try Nik's Euro Bits on 07980 639289, he sells Genuine Brembo Seal kits for the 2 piston Calipers ( I know cos I bought some of him even come with the correct rubber grease!) and Master Cylinders so maybe able to order 4 piston kits too, worth a try hope this helps.

cheers
Martyn

[Ginger Bear]

Oh Lordy............ There's some nice bitz there!

[KWACKERZ1]

If you struggle with seal kits try bearing specialist hydraulic seals would be available in the right sizes as brembo would not manufacture their own.

Also those calipers may be the same as some aprilia ones so try aprilia.

[Is Vic There]

Just stunning, wil be watching this thread, very good

[LondonZ1]

A bit more progress. I have now got the front wheel and brakes together. I had to get a custom spindle made and the spacers aren't quite right yet. The discs are 5mm thick and the outer groove in the caliper is about 7mm wide. That means I've got to get the spacers right to within about 0.1-0.2mm. You can't measure properly until it all goes together and by then it's too late. I'll have to get the spacers re-made but at least I now know it will all fit in the end. I managed to find some lovely billet Brembos in the US for a reasonable price, which I think set of the front nicely. It also keeps me closer to the original Sanctuary bike I am using as inspiration.




I've had a change of plan on the frame front. I am going to use Harris to modify the frame as my first choice firm was not replying to emails and Harris have been extremely helpful. I decided to buy a PMC stiffening kit, see photo. Like all the stuff I have bought from Japan, it is beautifully made. Harris will instal the kit and then weld on the rear shock mounts etc.
The swingarm is due from Sanctuary in 3-4 weeks.



The barrels and head are now refurbished but are away being painted satin black so no pictures yet. The engine will have sanctuary camchain parts and new MTC pistons. I plan to keep the camshaft although it would be nice to know who made; I'll measure the lift when I get it back and compare it with the std lift.

[mutz-nutz]

love the forks and yokes these are going to be smart as when put together keep the pics coming good luck

[kz900B1]

coming along nicely .Should stop well with those disks

[Is Vic There]

Love this thread

[LondonZ1]

slow progress....
Sanctuary have now made the arm and the other bits I ordered: rear caliper bracket, pillion peg hangers, torque arm etc. The arm looks great IMHO and will go off to Harris to get the brackets welded on as soon as it arrives in the UK. The engine is off being powdercoated at Triple S and assembly is scheduled for August. The tank will soon be en route to flying tiger so it's all finally coming together.

[martinz1000r]

some serious cash being splashed here. You either have a very understanding wife or are very good at creative accounting....