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KZ900-A5 (Project Bike)

Work in Progress

Moderators: paul doran, Taffus, KeithZ1R, chrisu

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Ultim8pc
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Re: KZ900-A5 (Project Bike)

#31 PostAuthor: Ultim8pc » Mon Oct 22, 2018 9:50 am

Looking good!
http://www.airevalleyclassics.co.uk
http://www.quick-glo.co.uk
ZRX1200r - on the road
z900a5 - on the road
z1a - to restore
z1000a1 - In bits
Z1000 MK2 - to restore
z1000ST - in bits

Philippe
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Re: KZ900-A5 (Project Bike)

#32 PostAuthor: Philippe » Tue Oct 23, 2018 2:30 am

I must agree, very nice work!
She's looking good.
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

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ADRIAN H
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Re: KZ900-A5 (Project Bike)

#33 PostAuthor: ADRIAN H » Thu Oct 25, 2018 8:35 pm

Looking good.
Who are you to judge the life I live.
I know I’m not perfect and I don’t live to be.
But before you start pointing fingers make sure your hands are clean - Jimi Hendrix.

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#34 PostAuthor: kawasaki_man » Sun Feb 10, 2019 7:31 pm

I've recently found that 3D printing has been helpful for making prototype parts and also a few final parts, such as the instrument pods. The following series of pictures show the process I've been through trying to create a new instrument console what will use new electronic clocks, but also trying to keep the spirit of the Z1 incorporated in the finished article. This is a work in progress, pods still need painting and the aluminium clock holder still has its white protective film keeping the brushed aluminium surface scratch free at this stage.

3d_printing-1.jpg

3D_printing-2.jpg

3d_printing-3.jpg



Here is the first mock-up using 3d printed console, version#1

console_mock-up.jpg


The current status- still needs pods painted and other fittings worked-on, but seems to be coming together.

final-1.jpg

final-2.jpg

final-3.jpg

final-4.jpg

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#35 PostAuthor: kawasaki_man » Sun Mar 03, 2019 6:39 pm

A few pictures with the latest progress. I have been working on a replacement battery box, oil catch tank and place for M-unit that allows me to use the Z1 side panels rather than the z900. Needed to work on the side panels to open then up to allow the K&N filters to be used. Finally managed to get all the parts to fit.

batbox1.jpg


batbox2.jpg


general overview_mar2019.jpg

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#36 PostAuthor: kawasaki_man » Sun Jun 23, 2019 7:40 pm

Just a quick update on progress, rear end now nearly complete, just waiting on the ISR rear disc, went this route since it seemed easiest to keep a brake and caliper holder and get the disc made. I've just received the rear wheel spacers and the rear brake toque arm so nearly ready to get the bike on its feet finally.[image][/image]
rear wheel-1.jpg

rear wheel-2.jpg

rear wheel-3.jpg

front_1.jpg

engine_1.jpg

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#37 PostAuthor: kawasaki_man » Sat Aug 17, 2019 4:16 pm

A few pictures to show some progress. I'm hoping that the final assembly of all main items can now commence. Just received the ISR rear disc yesterday so have now fitted the rear end today and hope to have the front end installed during the coming week. The rear shocks used are just a prop until I can work out what will fit.
rear wheel mount_1.jpg

rear wheel mount_2.jpg

rear wheel mount_3.jpg

rear wheel mount_4.jpg

Swirl
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Re: KZ900-A5 (Project Bike)

#38 PostAuthor: Swirl » Sat Aug 17, 2019 5:55 pm

Looks great, what gap have you got in that swingarm, I've a davida and on first assessment a 4 1/2" wheel with 160 tyre wont fit

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#39 PostAuthor: kawasaki_man » Sun Aug 18, 2019 8:09 am

Hi Swirl,
I discussed max tyre size with Metmachex before purchasing the swingarm, they said 160.

I have 160 tyre on a 4.25 rim, I've just checked the clearance tyre to swingarm and it is around 17-20mm on each side. Please see photo.
I hope this helps.
rear tyre clearance.jpg

Bill P
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Re: KZ900-A5 (Project Bike)

#40 PostAuthor: Bill P » Sun Aug 18, 2019 9:00 am

Looking good :)

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#41 PostAuthor: kawasaki_man » Mon Aug 19, 2019 5:36 pm

I managed to get the afternoon in the garage and now have the bike on two wheels. A great relief. I'll be starting on the new wiring this week, not sure how it will go since I have never done a complete loom before.
Some pictures of the procedure....
wheels-on_1.jpg

wheels-on_2.jpg

wheels-on_3.jpg

wheels-on_4.jpg

wheels-on_5.jpg

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#42 PostAuthor: kawasaki_man » Mon Sep 02, 2019 9:47 pm

A few pictures that show some further progress:
The wiring job is in full swing, I'm using an M-unit and have completed the low current part for all the switches. Most of the wiring for load items also done, just waiting on some "waterproof" connectors. This afternoon installed the dyna ignition and was able to check and adjust the timing with battery installed. Today I received the hydraulic clutch conversion (slave cylinder) from Falk in Germany.

wiring_1.jpg

wiring_2.jpg

wiring_3.jpg

wiring_4.jpg

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#43 PostAuthor: kawasaki_man » Sat Sep 21, 2019 5:53 pm

Made some steady progress in the past few weeks, getting close to an engine start.
Tasks completed: wiring finished, HT leads & dyna coils fitted, rear suspension fitted, foot pegs on, hydraulics for brakes and clutch 90%, carbs on, throttle cables fitted, instruments and warning lights done.
rolling_1.jpg

rolling_2.jpg

rolling_3.jpg

kawasaki_man
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Re: KZ900-A5 (Project Bike)

#44 PostAuthor: kawasaki_man » Wed Sep 25, 2019 6:02 pm

Here are the final pictures of the bike with bodywork on, briefly started the bike and seemed to run OK, however the APE cam plugs need to be sealed, oil was coming out!

I have my snagging list to keep me busy before taking it on the road. At the moment I've just attached an old Vance & Hines exhaust, but plan to have a new tail section made in due course when time permits.

final build_2.jpg

final build_7.jpg

final build_5.jpg

final build_6.jpg



Engine running!
start-2.jpg

kawasaki_man
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Location: Nottingham

Re: KZ900-A5 (Project Bike)

#45 PostAuthor: kawasaki_man » Thu Oct 10, 2019 12:19 pm

Snagging list fixed and the bike is running well now, no leaks from cam plugs. The bike is taxed and insured and I have completed 68 miles on several short outings. Just knocked out 35 miles this morning before the rain showers come.

on-the-road_1.jpg


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