Z1000R and Z1000J Project - Oven baked paint - carbonfiber

[RoyNorway]

Thanks boys!

Yes, I need to weld on the mountings for the shocks.

I got problems with the chain/sprocket issue.
Its to much offset. So I am working on that...

I received the Kerker 4-1 today, with rust stains, the ebay writings said "used" (only taken up from the box) so I guess its nothing to discuss.
Well, that only makes me paint it then.

The original paint is in fact Gun-Kote. Kal-Gard is pre Gun-Kote.

[ollie]

from the looks roy ,they didn't put much paint on that exhaust ,but i'm certain you will make it good
shame about the sprockets are they miles out ?

ollie

[RoyNorway]

You are right, isn't much paint on it.
I reckon its better after im done.

Those sprockets are far out, just over 20mm in difference, I have turned the rear sprocket the other way so it builds to centre.
The max offset I will go for without support is 3/8, 9.5mm on the front sprocket.






The chain also hit the frame, so maybe I need to but the swing offset to right...
I will not start on heating up the frame and clamp it thinner around where the chain hits...

But maybe milling down the sprocket bowl is an option, need to think and look what others have done.

[Taffus]

Just to say, WOW! learning lots from you Roy and this thread!
Keep it up!

[FER]

Can you move the sprocket in a bit on the rear wheel ? How much clearance do you have between chain and tyre ?









fer

[RoyNorway]

Thanks Taffus!.

FER:
I think milling down the rear hub will solve the problems...hope so at least.


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OK, it has been an long summer, now its time to start the bike project again.

The main things who needs to be done now is:

1.
TL1000R swingarm needs to be sandblasted and painted.
Also weld on the shock mounts before paint since I will use double shocks.
Find an solution for the clearance issue, will need to mill down the hub in rear wheel. Maybe do more in order to fix the problem.

2.
Rebuild the head, I will order some tools from Neway;

GIZMATIC-3

Valve Seat Cutter

3.
Some lightning issues front and rear, I will use LED everywhere except front light.
Also making an new twin headlamp from some damaged Bates buckets I bought on Ebay.

4.
Rebuild wire harness totally.

These are the main things left I think, but surely other issues will come up.

I will of course put out pictures.

Also I will start on the ELR, slowly and quiet...

[RoyNorway]

Happy new year everyone!

Now its time for me to continue the project, I have build me a mobile shed for my bikes, since its hard to get a proper garage around here.
Living in almost middle of town.






The ceiling light is Kawa green framed


Well, over to the project.

Earlier I decided to use the TL1000R swing, but now i am not sure anymore.

Here are some thoughts:

I am using 3/8 " offset Sprocket in front.


TL1000R swing:

Looks better, since it is no visible offset in the design.
But that makes it hard to fit because its necessary to mill/cut/weld the
sprocket carrier about 23mm, .09" .

And still the chain will hit the tire, maybe with a smaller tire 160 it
will be possible, but I am not sure.

I think that people who have use this swing have clamped/heaten the frame
in order to make the chain fit.


Hayabusa swing:

Looks a little bit strange because of the offset design, everything is
tilted to the right when looks from behind.
BUT, that makes it fit without any issues, its enough space on the chain
side if I am using original Busa chain /sprockets.

Otherwise with a wider chain it is a possibility that the chain will hit
the swingarm, not the bracing but the side of the arm.
Looks like it will be no problems with the bracing.

The only issue here is that the rim will be around 16mm, .63" offset...
To the right when looked from behind.

So, does the offset do something with the bike handling?

I dont know, i have been told that some bikes are offset from factory, and one person I know drives with almost the same offset, and dont bother, he cant feel anything.

Any thoughts anyone?


I am so happy that I am done with my mobile shed, and can continue with my bike!


Here is the TL1000R swing, as you can see it looks very similar on both sides, no offset design.


Hayabusa, you can clearly see the offset to right.







So I think I have decided to use to Busa swing...Puuhhh...
Now the plan is to clean it up, meaning cut off the old fasteners, weld on the new shock fasteners, and Gun-Kote it gold!

Also I have received the tools for to overhaul my heads, so that is also on the schedule.
Thank to 531blackbanshee for making that black crank, and US price on the tools!!!

[ollie]

hi roy and happy new year to you ,that is some kinda offset sprocket ,im no expert on how it would handle but i have seen a simular set up and the owner said he didnt notice ,but maybe some of the lads on here may be able to help better with regards to that problem ,glad the tools arrived and the new shed looks good

[RALPHARAMA]

The Mad Norwegian is BACK Yee Hi!!!

I was disappointed you had vanished from Zed land, Roy:D

I just love your refreshing and unusual takes on bike restoration and building - hows the oven?

Dunno why I'm calling you mad - I was riding home on a bike saddle covered in ice this evening .... for FUN !!!!

[KWACKERZ1]

Great project, Not a big fan of gold normally but looks great against the black.

With regards to offset wheels, DONT DO IT!! if you do you may find the bike will be ok in a straight line but the cornering will be well dodgy! It might work ok round left handers but not right handers, or vice versa.
With your wider choice of rubber this will only accentiuate the effects of it being offset.
Those people that dont notice offsets are probably running skinny rims wheer the affect would be less, or are lying, or just not riding hard enough to notice.
Its just not right and could be dangerous.

Please dont waste of all the time and effort you are putting into building a great bike by compromising on something you know is wrong!

Having spoken with Big green bus about fitting a zrx swing arm he had to machine the wheel/sprocket carrier to restore the chain run and miss the swing arm, Could you not run a narrower chain, machine the wheel and run a narrower tyre to give you the room to play with?

[brian 450]

Hi, i agree with kwackerz1 dont do it!!! it will drop in a corner fast one way and you will have to fight it the other. If you take a look under trick z1000 on this forum you will see my bike i have fitted a 6" wheel with a 190 tire. What i had to do was machine sprocket carrirer down and the hub and it all lines up nice. As regards to a smaller chain it as not advisable to use a 525 chain as they are for dirtbikes and bikes of a lot less power than a Z and they will break. Brian

[RoyNorway]

Ollie: Thanks!

vduk: Thanks! , you know, mad people have a tendency to suddenly vanish, and then be back again hehe.

And yes to all you boys, I agree on everything about that offset.

I have done further measurements, and now if I cut more on the left side of the Busa swing, there is only 6-8 mm to take on the sprocket carrier, and that should be within the limit on what that carrier can be milled without any problems.

And after that is done its no offset.

I allready earlier did some shaving on that swing, so this is just a kind of termination of the job.
Pics are coming on that.


Were X marks the spot.

I am pretty sure that I can use the Busa arm, so I have started on the job to find out where to weld on the fasteners for shocks and the mount for the torque rod for the rear brake.


There where still air in the old shocks after been stored away for almost 20 years.


460mm is the original measurement from the Kawa swing, from center pivot to center shock mount. More or less...




You get the idea where the torque rod are coming.


X


Here is the original rod fastener.

[RoyNorway]

So, here are the shock fasteners, and brake rod fastener, 531blackbanshee, at the KZRider.com is gone to make them for me. Thanks Leon!







Using GSX1100 Bushing;


Here is the brake rod;




I made the blueprints with this program, in the free version its more then enough for to make these drawings;

Google SketchUp 7

[Ginger Bear]

Hi Roy,
Fantastic project.
I see that you are having real issues with your swinging arm choice & chain alignment.
This is what worked for me, I will post pictures if you would like me to.
It has already been mentioned in this thread about the use of a GSXR 600 SRAD arm.
That's what I have fitted to my Z1000A1. To start with it fits straight in, with no need to remove any material around the pivot point, in fact you will probably need to add a couple of shims.
I have a ZX7R wheel fitted & centred with modified spacers. I have a 5/8 offset front sproket then had 8mm milled off of the sprocket carrier. 180 tyre fitted.
Chains & sprockets were supplied by Debben Who were extremely helpful with advise on sprocket size/drive ratio.
Hope that's of use.

Also I see you have a valve seat cutter, Again I will tell you of my own experience!
Had head refurbed, seats cut. Looked good, then the problems started
Seats cut mean the valves sit deeper into the head, requiring a smaller shim. When it became apperent the clearance was too small for a 2.00 shim, I removed the valves & ground down the stems (as per kawasaki manual instructions). Still not enough clearance, so a new set of valves was purchased, that had a bit more meat on the seating face. some of these still needed to be ground down

All I can say is Cut With Care

Look forward to the next installment

[RoyNorway]

Thanks for your advice Ginger Bear.

I think I have overcome the alignment issue now, waiting for more paint to finish it.

Thanks for your advice regarding seat cutting.

I read about that issue in the original Kawa book, and I will be very careful when I am doing it... ( its gone be very exciting, have not done it before... )

But, I will rehearse on an old head and valves before I do the real job.