Club Restoration

[davy thomson]

Sneaky we pic of a GT there. I would love a GT550.

[Bill Newman]

Time for an update - its been a while as I have been over to IOM to watch a bit of road racing.

After collecting the paintset, I cracked on with the peripherals - I did not want the brake lever to stop against a bolt so used an allen bolt with a plastic chrome insert



Then my first real setback - I broke the stud that the dome nut fixes to hold the brake arm - here is a temp replacement holding by one thread. After putting up a shout for help I decided to contemplate my options before setting about the repair. More to follow...






Kickstart rebuilt with new knuckle assembly





Then started on the clocks - new foams fitted



Then the clocks themselves



With stainless replacement screws



And LED idiot lights for a brighter glow - and less resistance



Result is pleasing







Then to the winkers - bit of wiring repair with one of those ebay kits works really well





New stainless brake rod kit is really good quality (from Z1 Enterprises)



Clear heat shrink on the stands to protect the chrome





Next was to fit a genuine clutch cable to try and overcome some of the stretching problems I have had with a cheap replica



L/H side now completed with starter cover on



Now the chain guard - supplied through the club



It is a really good fit

[Bill Newman]

Some more...

Seat lock fitted



Now to refurbish the air box - cleaned the mesh filters with petrol



New foam filters for the drain bungs





New drain pipe and clip



And exhaust clip





Relectors back on



Then a morning off whilst I go to the Pre-Germany meet up





Now its time to reassemble the carbs









New cotton reels were my prize in last years Z1 Yorks Rally



Then to the front brake - I had not had a good result with anodising because of the nature of the alloy so decided to repaint instead. I know it is spoilt by bleeding so I power bled the system off the bike and then masked and painted. This will do for the summer until Mikey and I can concoct a different treatment over next winter!!







Did not want to put paintfilm on the frame where it could be seen (and next to hot exhausts) so heat shrinked the clutch cable clamp to protect the paintwork. It works very well



Next jobs are to finish the winkers, fit the exhausts/paintset and replace the seat

[Padders]

Excellent work Bill I had to put me shades on to read the thread there was so much bling!!

Sorry about the brake lever stud never seen one of those go before.

Look forward to the next update.

[Bill Newman]

Excellent work Bill I had to put me shades on to read the thread there was so much bling!!

Sorry about the brake lever stud never seen one of those go before.

Look forward to the next update.

Thanks Ian - here is the next instalment

Rebuilt the caliper with freshly anodised plate and new rubbers. The seals and dust rubbers were a nightmare to get back on



And new pads




End product looks OK



As does master cylinder



Clutch perch on - thanks to Tlc




Gave the HT cable clamps the same treatment as the clutch cable clamp



Again, I am pleased with the result



Not much to put on now





US rim



Throttle cables on



Oil filter and new drain bolt in



New drain screws and pipes for the carbs



Now for the body work - new rubbers for the duck tail



Along with rechromed helmet hook



Looks OK



Along with the grab rail



Side panels have new badges and clips



Held with a whiff of silcon - decided to put the KZ badges on to keep it authentic



New studs to the exhaust clamps



In readiness for the exhaust fittings





Refurbed carb exhaust now on



But have to sort out that brake stud first - cut off the remains with a cut off tool and got it flush to the shoulder







Then a centre punch followed by a 4mm pilot hole



Followed by a 6,5mm hole and a M8 tap 20mm deep.





End result after the threaded bar has been thread locked into place and a new dome nut fitted



Next job is exhausts, tank and seat

[pertonpc]

Great work Bill
Won't be long until she's back running again.

Cheers from Mark

[z1bman]

excellent job bill. should look stunning when its finished

[Rich]

The carb pivot end plug doesn't seem to be seating right.

Don't have the LEDS too bright for the idiot lights as they (high beam especially!) get annoying when riding at night.

[Z1parR]

Absolutely stunning Bill

[Bill Newman]

The end is in sight and I am in a hurry to get there - Germany is 3 weeks away and I have not had it running.

Time to open the boxes - I bought these 3 years ago on German Ebay in anticipation of this day





One down and three to go...



One side completed



and finished getting the zorsts on



Now to rebuild the petrol cap - Mikey took it apart to chrome it and I had no idea how it went back together



I worked it out in the end



Petrol tap fitted




Replacement decals on





Refurbished the Hazard warning light









Now for the seat



Detail is excellent



Some rubbers on the number plate fixing



And its finished













Save for one finishing touch





I am proud to wear this badge...

I filled it with oil, checked for leaks, kicked it over 15 times or so and added the 97 octane. Turned it once on the starter and it fired at the top of the second prod - well pleased.

Rechecked all the torque settings yesterday and the remainder of the fittings and took it down for a ticket today. It passed no problem - but they did not like the US spec glass in the headlight....got an advisory after I taped it off.

Managed to do 15 miles home this afternoon and after fiddling with the carbs most of the morning, its runs a treat.

Bring on the Z Rally.

I will make one more post( tomorrow) before finishing this thread - to acknowledge all of those members who have had a material input into this project and with out whom I would not be at this point.

[mikey]

Absolutley fantastic bill cant wiat to see t at the germany rally
glad to have played a small part in it.
Sorry about the fuel cap mate should have put it back together for you

[Tonto]

That's a work of art Bill - truly fantastic looking bike.
Cheers Tim

[garyd]

WOW....Looks just like thw one I bought new from Daytona....all thos years ago.

Your my hero

[tlc]

Thank goodness for that Bill.

I thought I was gonna have to give you a pillion.

[Flying Tiger]

Bill that looks absolutely gorgeous, can't wait to see it in the flesh!