Double the troubleZZ. AMA style Racecrafters Z1000 (completed) and Moriwaki Z1R Turbo.

[zed1015]

Finally got round to the getting the Z1R's front end in using some substantial 48mm Yamaha FJR1300 forks and yokes mated to a zx12r front wheel.
Started by tackling the FJR steering stem with the plan to either use a modified Z stem or make a new one but when it arrived the FJR stem looked suspiciously familiar.

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And when measured up and compared to a donor Z stem I already had it turns out it takes the same bearings and is the same length between them so that was a surprisingly easier job than expected as it slots straight in

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So slip the legs in ready for the wheel.

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The ZX12 wheel takes a 25mm spindle and the FJR forks use a 20mm spindle and the wheel has the same issue as the rear wheel with a captive 12mm wide bearing held in with a circlip that you can't get with a 20mm hole .

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So on the left I have kept the bearing which is now sleeved down to 20mm with a top hat reducer, made a new 3mm shorter spacer tube so I can fit a 15mm wide bearing of the correct 20mm bore on the right.
I may revert to the original ZX12 bearings for both sides and just make some combined wheel spacer/reducers for the final build later but this does the job for now.

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And with some new wheel spacers of the correct size turned up the wheel drops in.

The chunky Yam lower legs run close to the wheel and won't allow the use of the dished Kwak brake discs so i'm going to have to either find some that fit with less offset or more likely make up some adaptors for some flat XJR ones or the like.
Should have something on two wheels to look at soon though.

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[zed1015]

Original FJR top yoke and bars are nasty looking things

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So used another FJR bottom yoke, removed the stem,machined off the lockstops and drilled some holes to take some one off bar clamps

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[zed1015]

Bar clamp begins life as a lump of ally bar

Cut in half , bolted together and bored out 22mm along the join

One half got a skim so that they clamp up on the bars

Bolted on and functional but looks a bit too angular, even for a Z1R, so need to get a bit of shape into it.

Start by boring a clearance hole for the stem nut

Then some trimming to match the front curve of the yoke

Getting there

Looking something like

And after a few hours of hand shaping and finishing I can mount the bars

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[zed1015]

On its feet at last and wheeled into the light to get a better view..

Pleased with the way the angled spokes of the 12r wheels tie in with the Z1R styling.

[Pigford]

Stunning work as usual mate

[Swirl]

Love it and you make it look so easy

[davejames]

The quality of your workmanship is stunning Rob

[Mr Puffin]

Nice that sits really well

Theres quite a few photos missing further up the page

[Swirl]

Sterling work as usual

[zed1015]

Nice that sits really well

There's quite a few photos missing further up the page

Yes! They were all missing yesterday after the site went down earlier in the week.
It's happened to the most recent threads.
I'm slowly reattaching them one post at a time when I get the chance.

[Stogmuller]

Very,very nice
Where did you buy the rotabroach cutter from,?

[zed1015]

Very,very nice
Where did you buy the rotabroach cutter from,?

Got them off Ebay around £14 each.

[TiBolts]

Very cool projects! Interesting to see and follow

[zed1015]

For the "bonus bike" I've got some ZX7R usd forks that can be seen in the background of this pic.
These were thrown in when I bought the Z1R frame .

First job was to fit the Z1000 stem which I didn't need for the Z1R.
It's handy that the inside diameter of the ZX7 stem is the same as the OD of the Z stem so it's a simple job of machining the ZX7 stem flush with the bottom yoke where the bearing sits and pressing in the Z one.

Then after boring out the top yoke to take the top of the Z stem

The yokes are jigged square by bolting the legs and top yoke together and a ring of weld is run around underneath the inside to secure.

As can be seen in the pics the short ZX7 forks had previously had some 55mm extensions welded on to the fork tops to get some reasonable ground clearance when fitted to a Z frame.
This was a fairly nice job but not well thought out because as well as making the preload adjusters inaccessible were also ineffective as you couldn't use 30mm of them because it pushed the stock bottom yoke off the straight part of the leg.
Maybe the plan was to make a stepped bottom yoke to account for this.

I had already got a set of stock yokes so to solve the preload access issue I machined off the extensions excess 30mm that won't be used.

Then to regain the lost 30mm and some decent ground clearance I machined up an extension that screws to the damper rod

There's just enough unused stanction above the fork bush to make this possible.

Now needs some bars and clamps

[zed1015]

For the cost of materials and time It was cheaper just to buy a set of a ally risers off ebay.

They were a little tall so saw the access off

And fly cut the bases flat

They were a single 10mm bolt mount so I continued the four threaded 8mm bar clamp holes right through, jigged the risers parallel and marked the yoke for drilling.

Then spot faced the underside for the allen bolt heads.

Bars on

I'm using a matching ZX7 wheel to keep things simple but not using a mechanical speedo so just make up some alloy wheel spacers

And it's in