DROUIN Supercharged Z1000.

[zed1015]

This was really bad news and would mean an engine strip which gave me thoughts of giving up and selling the project. After an hours swearing and kicking anything but the bike i decided to get my brain in gear and try and sort it without mass destruction. I came up with the idea of drifting the leaking plug out from inside the engine and out through the frames mounting lug. After draining the oil and pulling off the sump and oil pump i found there was luckily just enough room to get a suitable drift inside the filter housing and into the oil gallery.



After a few taps the plug moved very easily and emerged out of the frame lug ( Too easily in fact and the donor motor was a minter, untouched from the factory when i got it )


And here it is.


A swift session on the lathe produced a slightly larger replacement which was duly fitted and everything was re-assembled.


I've now replaced the oil so i'll have to wait till the morning to be sure i've cured the leak ,Then i'll be a happy man again.

[Steve R]

Never heard of that one before
These things are sent to try us
Good job you are so talented
Good luck for the morning

[zed1015]

Never seen it myself and i've done 100's. Must have been a friday afternoon job.

[Ginger Bear]

Zed1015,
Got some more good news for you. Got home today to find two lovely 19t 5/8 offset sprockets
Already checked they fit with no clearance issues at all
PM me your address & I'll get one in the post to you tomorrow.

[zed1015]

Oil leak is cured and now finally got round to fitting the 19t 5/8 offset front sprocket today. Though this threw up the small problem of the steel side cover not fitting due to the sprocket now sitting outboard by an extra 15mm . This would mean chain lube etc would not be contained within this area and fly off all over the place.


After a bit of head scratching i came up with idea of extending the casing by taking a slice off a spare cover .


And after fitting hollow location dowels it looked like this


Three longer cap head bolts later the side cover now fits with loads of clearance,


Outrigger plate refitted, hydraulic clutch bled and hopefully all this is now finished and can remain undisturbed and ready to go.

[Pigford]

That looks so sweet..... pure art

[Big John]

Stunning !!

[Ginger Bear]

Come on Zed1015, is it going yet

[zed1015]

Been working on sorting all the odds 'n' ends that need doing . Can't rush these things you know .Got some more pic's soon to bore you with . and really need to sort the paint but still don't know what colour or who will do it ?. Only then when EVERYTHING is done will i start it. Actually it's driving my mates bonkers coz i could have fired it up ages ago but i always fully complete my builds first, otherwise i'd be tempted to start running around on it and loose the incentive to get it properly finished.

[mikey]

More pics to bore us with?? bore us all you like i find this stuff amazing half of it i dont understand and i dont have the ability or equipment to do this kinda work but i can appreciate your skill so come on get posting.

[GUYZED]

What ever paint scheme you choose it's got to be red.

[zed1015]

Ok. Here's what i've been doin. With the blower fitted there wasn't room for a fuel tap in the original place and i didn't have a zed tap anyway. So i've had to weld over the original mount and put a new mount further forward to take an unknown high flow tap that i found amongst my hoard of bits.


Trouble started when i spotted that this tap had no reserve so i've had to modify it slightly with home made internals and a handle off another tap. Original handle can be seen on the right and bit of brass bar will be the on and reserve level tubes with gauze filter soldered on when i source some. I've also fitted a small spring and ball bearing (out of a grease nipple) to form a detent so positive on /off/reserve positioning can be felt with a click.


Tap shown in position.

[zed1015]

While i was butchering the tank i removed the original cap mounting and beat the recess flush to the surface. Then i cut out the opening and fitted some threaded rivnut inserts.


To take my home made flush filler cap.

[Ginger Bear]

Blown away again!!!!! Every step of the way :resp

[BShaw]

Don't get much time on here but just spent nearly an hour reading this, very interesting, very clever, if I had a hat I would take it off to you.... looking forward to seeing it finished.
Regards