My new project

[paul doran]

I had one of those years ago
brilliant bike
best of luck with it

[DavidZ1R]

Bugger, the post ' sarted at last' should be on this topic, if anyone out there can put them together, please

There you Go David..... Best I could do.... GB

Well made a start with the bare bones, been collecting, plating and coating bits, found that the new frame wont take my american side stand, oh well, but coming on, no doubt will find more that wont work, if the link works thanks Will.

http://www.flickr.com/photos/97521772@N05/
_________________

[DavidZ1R]

Cheers Ginger, good to know someone knows what to do

[DavidZ1R]

Did a bit more on her today, need to clear some space in the garage so I can start on the engine, cleaned out the air box today, found a dead mouse in it, an american one at that!


http://www.flickr.com/photos/97521772@N05/

[DavidZ1R]

http://www.flickr.com/photos/97521772@N05/


Well have done a bit more to my KZ550 project, have rebuilt the engine, thanks Keith Z1R for tool help, refitted it, put a few more parts on it, this Christmas I will be cleaning and refitting the carbs, the zorst's and if I get time the harness back on, all good fun, oh then sending off the body work for painting.

[Big Fluff]

That looks fantastic!
I had the predecessor to yours, the 3-disc Z500.

I must tell you now, before it happens.....
When you put the 'choke' on, look down through the back of the TK22 carburettors and you'll see the main choke slides and very small spring-loaded 'butterfly' flaps (if they're still there) in the middle of each choke slide.
I would strongly advise that you remove these little bastards before they cause you a great deal of heartache.
They fracture over time then get sucked into the engine. They are small enough to pass through the inlet valve, but NOT the exhaust valve, so this is when the piston hits the open valve due to the choke flap holding it open.
I know, it happened twice to me on my baby Zed. The bike will start and idle cold just fine without them.

Soon as my ELR is finished I'm on the lookout for a Z500

Will

[Z1parR]

Lovely job David , as we've come to expect from you

[DavidZ1R]

That looks fantastic!
I had the predecessor to yours, the 3-disc Z500.

I must tell you now, before it happens.....
When you put the 'choke' on, look down through the back of the TK22 carburettors and you'll see the main choke slides and very small spring-loaded 'butterfly' flaps (if they're still there) in the middle of each choke slide.
I would strongly advise that you remove these little bastards before they cause you a great deal of heartache.
They fracture over time then get sucked into the engine. They are small enough to pass through the inlet valve, but NOT the exhaust valve, so this is when the piston hits the open valve due to the choke flap holding it open.
I know, it happened twice to me on my baby Zed. The bike will start and idle cold just fine without them.

Soon as my ELR is finished I'm on the lookout for a Z500

Will

Cheers Will, your ELR looks the dogs as well, I was warned about the little flaps on the choke slides by Dave Marsden, I will take them off if the bike will start up ok, I will bow to your experience and learn from it, will post pics later. Ta

[jphaynes669]

Looking good david, , its coming together nicely.

[DavidZ1R]

Well done the carbs, as best as I could, ultra soniced the complete gubbins with fluid recommended by GB, thanks, fitted complete refurb kit, jets etc, one point tho, the little fuel plug was smaller than the original, they kept falling out, so I bent the tang a touch on the floats, ok now, did I do right?

Against the best advise from Big Fluff, I did a complete check on all the butterfly flaps, they were all sound and showed no sign of problems, the engine had done 22k so I put them back in, I hope I did the right thing Will

http://www.flickr.com/photos/97521772@N05/

[jphaynes669]

Hi david,, might be an idea to just check the fuel heights on all the carbs, adjust as required and then vacume balance. Big fluff spot on with the advice on the choke flaps. Havent had any probs with mine but worth checking regulary. Look for fractures on the flap itself and security of the spring/pin set up. You can remove inspect these parts with carbs fitted ,,, just do them a pair at a time,,, nearside then offside. I got a couple of set of carbs so let me know if you need any bits

[DavidZ1R]

Cheers Jeff, did the balance thing, took three hours to get the levels within 2mm of each other, ended up removing the new fuel valves and seats, the valve kept sticking or dropping out! feckin things, anyway all back together, no air screws to refit as the USA carbs dont have em!, going to put them back on the old girl next, and then tackle the zorsts. Where abouts in Northants are you? I used to live in Rushden many years ago.

[DavidZ1R]

Well done a bit more over the holiday, cleaned and refitted the carbs, what a job that was cleaned up the pipes and put them back on, including the right hand one I got off e bay for £9, bargain ! there are patches of stain on the left hand pipe, think the chrome has been worn off, best I can do tho, next job the main harness to clean up and refit, then new battery and hope she lives. Paintwork next to go.

http://www.flickr.com/photos/97521772@N05/

[j.b]

coming along really well David

have you found a paint code for the bodywork? as i need to do a few bits on mine too

[oldtimer]

Looking really well, I am just waiting for the paintwork to come back for my Zephyr to complete my project.