Been there, done that and it's not that simple.. You need the output bearing, a spacer and seal which is available as kit from APE. The bearing is a special with a groove for the half moon locators so not available anywhere else. BUT that isn't the whole story. You also need to machine the shift dru...

Thanks both Al and zed1015, that has been a great help. One final question , I am presuming from the catalogue and the picture of zed1015's bike that the RPK3190 is designed to run with no outer cover. Is this correct? Yes! It bolts to the cases with the stock gasket and has an oil seal on the cran...

I would add that with the STK310 self generating ignition you can't spin the motor fast enough to produce a spark with the kickstart ( been there tried that ) and you would either need starting rollers or bump starts..

Thanks Al, running a standard alternator but also have a healtech electronic quickshifter so revs don't really drop between shifts. Sounds like something I should look into for next season. This is the RPK3190 kickstart only version that i run on my alloy cafe. The oil gallery issue of the starter ...

You need minimum 2d.
Tap and insert tool will suit any M6 x 1mm coil inserts.

You can get an m6 helicoil in those dowelled camcap holes without damaging the locating hole.
I've done hundreds.
The stripped holes usually don't need drilling for the helicoil tap either.

New rear caliper pistons arrived along with seals etc SUNP0492.JPG So forged ahead and got it rebuilt and fitted along with the torque arm then finished off by replacing the original bolts with some stainless cap heads that have had a clean up in the lathe to remove the lettering etc to match the r...

I don't know if this is of any help whatsoever, but there is a guy on a Ducati forum that I frequent who has built a replica of a Kawasaki endurance racer with what I seem to remember, a very similar alternator/charging system. It is a truely brilliant piece of work ! Potentially it could be worth ...

Been scouring ebay for ages for a decent set of calipers to fit the ZX7 forks when i spotted a nice set of Tokico six pots listed as GSXR for £150 or best offer at a BMW breakers which were already fitted with stainless bolts and banjo's . The were the only non BMW parts in their listings so chance...

Few more bits of the puzzle done. Freshly powdered starter cover and extended sprocket cover fitted. SUNP0469.JPG SUNP0470.JPG And the underseat tray in situ with components for the minimal electrics. SUNP0480.JPG 30amp toggle switch on right for main power, solenoid for the starter with integral 3...

Just got the last few pieces back from the powdercoaters. The four odd bits on the left are the ''Y' shaped mudguard stays, rear mudguard and clutch cable guide from the Zeph1R cafe which were originally painted and looking a bit ropey and stone chipped after 10 years so thought i'd have them done ...

ALL Z1 through to Z1100 aircooled fours have the positive neutral finder no matter what year or country. Sounds like the lockout bearings have been taken out as they need centrifugal force to release them all and just rocking the wheel shouldn't be enough to get 2nd and above. As for the neutral lig...

It's impossible to get the the selector drum etc wrong.
It sound's like your 5th is actually really 1st and you have the gear lever on backwards or rearset linkage reversed if fitted..
The lever should point forwards.

Another little job ticked off today. Sourced the proper AMA spec plastic front numberplates for both bikes so the dummies i made for visual mock up can be trimmed down to form the combined number plate mount and dash support. SUNP0434.JPG Made use of the mill and my newly aquired rotary table to ch...

As Chris says. There's nothing wrong and you can only get 1st and neutral at a standstill. Once the transmission is spinning you can get the rest of the gears due to the 3 lockout ball bearings being released centrifugally. Removal of the ball bearings allows all gears to be selected at a standstill...