ZR750 Zephyr strip and tidy

[oldtimer]

I managed to work photo bucket thanks to tlc's tuturiol.


I know its not a Z1 but thought I would share my project if any one is interested.

What originally started off as a strip and tidy of my 750 has turned in to a major strip down as the frame is rusty and needs blasting and powder coating, the pictures just dont show how filthy, oily, rusty and neglected this bike is.



In transit.



Loads of rust where mud has collected.








When I took off the tank, something was rattling inside, I thought it would of been something broke off the fuel level float, instead it was a AEG Trovan 300 which after searching appears to be a transponder possibly off the data tag.



The swinging arm and underside of the frame andengine is covered in 17 years of mud and oil.







The calipers were seized solid with rust, I had to remove the calipers to push the bike.






Rocker cover gasket has definately been leaking.

[Pigford]

Wooooooooooooh - those nice wheelz

Nice little project

[oldtimer]

Wooooooooooooh - those nice wheelz

Nice little project

I would love to get the wheels rebuilt with stainless spokes as I think the spokes will let the bike down when it has new paint etc but I guess it would cost too much.

[kev edwards]

Bloody hell you even have someone hiding in it,

I will watch this one as i have a c1 model with the jaffa paintset.

[oldtimer]

Todays progress, just need to remove the oil cooler and then I can remove the engine, not sure if to lay the frame on its side or as the manual suggests to leave it on main stand and use a trolley jack under the engine, seems a bit fiddly to me, what do you guys suggest?

Whilst removing the forks I noticed how notchy the head bearing is, it rotates freely and then hits a tight spot before becoming free again, not sure if top or bottom bearing so will change both to be on the safe side.

[kev edwards]

Take the rocker cover off first and cover with clean rag, i done my brothers last year using the jack method it's still a bit of a wriggle but i got there, had to have help putting it back, getting up on the bench on my own was haemaroid moment almost.
I done his with the front and back ends on though you will probably find it easier to lay it over as you have stripped it all to just frame and engine.

[oldtimer]

Took the engine out tonight, laid the frame down and removed it that way, came out quite easy, I then replaced the frame over the engine a couple of times to see how it would go back on again, when I do reinstall the engine I will remove the rocker cover as that little bit of extra room will prevent the frame from getting scratched and may make my life a little easier.

I need to sort out all the bits I need blasting and coating and get them up http://www.wilkinsonspowdercoating.co.uk/

I will post again when I get the frame back.

[oldtimer]

Quick update, just a bit of cleaning and polishing whilst waiting for the frame to come back from the powder coaters.















Cant wait for the frame to come back so I can start reassembling.

[oldtimer]

Frame back today, could not resist putting a few bits on, cant do a lot until I get the engine back in but waiting for a dry day so I can have a go at soda blasting.



The stand springs and axle clips were cleaned up on my polishing wheel and came up far better than I ever expected.

[jphaynes669]

A mate of mine in taunton restored a 750 zeph, they are a much underated bike and becoming quite sought after. Have a good look around the fuel tank...the seams along the bottom and the weld around the filler are suspect and the tanks do suffer with rust..
Good luck with the build,, hope it all runs smoothly

[oldtimer]

Thanks Jeff, the tank is fine on mine luckilly, even inside the tank is very clean, I do intend to treat it with something or put an additive in the fuel because as you know these tanks are very rare to come across secondhand.

Regarding replacement tanks, webike japan offer a Z1 style tank and side panels to fit on the Zephyr, there is a 750 Zephyr on ebay now with a Yamaha FJ tank fitted, it is a shame that Zephyrs are getting scrapped just because of a shortage of tanks and exhausts, they are a good reliable machine with a proven engine.

[andyb1962]

This is starting to look very promising, cant wait to see it finished
good work!

[kev edwards]

Thanks Jeff, the tank is fine on mine luckilly, even inside the tank is very clean, I do intend to treat it with something or put an additive in the fuel because as you know these tanks are very rare to come across secondhand.

Regarding replacement tanks, webike japan offer a Z1 style tank and side panels to fit on the Zephyr, there is a 750 Zephyr on ebay now with a Yamaha FJ tank fitted, it is a shame that Zephyrs are getting scrapped just because of a shortage of tanks and exhausts, they are a good reliable machine with a proven engine.

that one on fleabay has a xjr 12/1300 tank on it, i use a stabilizer in my fuel and completely drain the tank twice a year, i love my 750 zeph it does everything better than my old thou except a grin thet comes out of the crash hat, but it is fun to ride.

http://www.ebay.co.uk/itm/161024047118? ... 1436.l2649

[paul doran]

great project this

I just had a look at that one on Ebay
it is certainly attracting the bids

[oldtimer]

A little more progress, I tested my new soda blaster, dusty job but it had to be done, just need to polish the engine then can get it back in the frame.