Z650 rebuild.

[Crofty]

Thought I would post something, now that my frame and other bits are back from powder coating. Braved the snow and went over to pick the stuff up this morning and got it into the shed before it started blizzarding again.
Started fitting a few things and managed to get head races in, rear s/a bearings and a few rubbers. really need to get valves shimmed so I can motor in before I do anything else.
Heres some pics.

Frame

Top race installed.

Electrics bracket having threads cleaned.

Rear swingarm bearings pressed in.

[mick znone]

hope you have a heater in that garage Crofty, im thinking of a z650 myself, i shall watch this one, frames looking good.

[Crofty]

No heater Mick, just a Rab down jacket. It would be like setting fire to pound notes with all the draughts. Looking at nailing a rubber strip along lower of door edge. Plenty of bits available for 650s, except for some engine parts like o/s pistons, unless you go Wiseco. The cost of bottom end bearings and std size piston rings is astronomical, unless someone knows something I don't, Jim

[v70z650]

Hi Crofty

Just thought that I would post a reply as I am just starting a z650 rebuild myself (+ GPz750 engine, wheels). I have a couple of pictures on the 'New Here' thread (see link below) and will be starting a project page in due course (as soon as the weather improves enough to get back in the garage). Maybe keep in touch for help, tips, screams of frustration etc.

http://www.z1ownersclub.co.uk/forum/vie ... ht=#112685

Rob

[Crofty]

Hi Rob, your bike looked pretty good pre rebuild, but aware of the finer detail things like rusty bolts, perished rubber. A bike sure is a lot more than frame, forks, wheels and an engine. I have been keeping warm in the shed today by filing the letters off stainless bolts and sanding them smooth. For less than £20, I fitted out most of the frame stuff (less long engine bolts), mudguard bolts, front fork lower cap nuts and a few more like chain adjuster bolts etc. I will keep an eye out for your posts and don't hesitate to ask any questions, I am still learning about 650s, did a Z900A4 up in the late 80's though.


Electrics mounted with stainless bolts. and I know the wires are poked through the wrong direction after looking in manual

Front forks with stainless nuts and bolts.
Jim

[v70z650]

Looks like you are doing some great work Jim and you have my full admiration for getting into the shed in the current weather. Will keep in touch.

[Crofty]

Current heat wave conditions have meant a bit more time spent in shed. Managed to paint handlebar switch gear housings, been cleaning the gold paint off the mags, filing and polishing more stainless bolts. Made up a under seat splashtray to allow removal of rear m/guard. shrinkwrapped the dynacoils brass spacers. Rebuit the calipers and front forks. Philpots did as great job of rechroming the old tubes. Today went over to platers and picked up first lot of oddments that got zinc plated. Just a few pics to show. Crofty


Caliper rebuilt


Painted switch housing.



Master cylinder window with watch glass sealed in.

[Taffus]

Good progress mate!

[GUYZED]

Looking good there Crofty...keep the pics coming.

[1beelee]

great job well done.

[Crofty]

Progress has slowed a bit, as I wait for the chrome stuff to come back. I was told it would take 8 to 10 weeks. Seems like a long time, but the stuff they showed me looked good and they have done stuff for Rolls Royce.

http://www.allenchrome.com/aboutus.html

They were very quick on turnaround for the zinc stuff I had done, but thats easy stuff for them.


I have done the footrests.

The wheels are back in black.

[Crofty]

I have rewired the left hand switch to suit UK horn/pass button.



and resealed the master cylinder window in using a crystal watch glass. I blanked off the outlet and filled it with brake fluid and its held fluid with no weeps for over two weeks. I also sourced a old m/c with a pitted bore and cut the old window free (so I have a spare now).

[Crofty]

The speedo and rev counter have been respayed black and the mount bracket powder coated, new bulbs and stainless fasteners.







I have pulled the top end off the motor, which I am glad I did. The bore was not in good condition and luckily I have a spare set, which are being honed today, before I get a fin welded and then off to vapourblasters.

[Redbeard]

Really impressive work, its going to look great when its complete. Did you paint the wheels yourself? If so, any pointers as i'm going to repaint mine and they're basically the same as yours. Many thanks.

[floydsz1]

looking good jim,
When i rebuilt me z1a i put the bits i had just picked up from the powder coaters on the kitchen table, i thought i'd try the swing arm in the frame to see what it looked like, 4 days later i had to get a mate round to help me lift it off the kitchen table and carry it into the garage as all it needed was the wheels and engine etc putting on, Was nice and warm in the kitchen though.