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Engine rebuild

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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tlc
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Engine rebuild

#1 PostAuthor: tlc » Wed Feb 10, 2010 8:25 pm

The time has come to clean my engine as a previous owner decided that silver hammerite would be a good idea to cover up the dirt.
Also I wasn`t convinced that the camchain would be in a pretty state but found on disassembly that all is pretty good.
My engine at 32 years old has it seems never been stripped, so it was nice to be the first to delve into the depths.
I know many of you have done this before but I thought as a virgin engine stripper there may be some relevance to other novices as to the pitfalls or otherwise of a hamfisted mechanic having a go at engine disassembly / reassembly.

My normal work involves pistons of at least 225mm so this is much more delicate work than my 10lb hammer is used to.

Here is the bike on the bench.

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At this point I have got the barrels and head off and all looks good so far.

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The pistons were well carboned but apart from that looked really good.
The camchain gubbins were worn only on the rubber parts so I decided to replace all of these as a matter of course.

The head looked pretty good but I decided to entrust any repairs to an experienced Zedhead.

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The barrels looked pretty good.

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As we stand at the moment the head is with Dogs and only needed one valve guide and a skim. The rest of the engine is with Doug Cox for the vapour treatment and the carbs have been completed.
I should at this point thank Mr Cox for vapour, Mikey for polishing and zinc late, NRP for the jet kits and Jeff Saunders for the float bowl drain screws (NOS) :D And me for all the rest. I should say that not wanting to spend too much money I decided to do the carb rebuild myself but found I still spent probably £200 plus so reckon that Dogs estimate of £350 means he`s working on £10 per hour which seems good value to me.

Anyway, here are the carbs all done.

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That`s it so far. Mucho shopping to be done and the update, and many requests for advice, will be coming soon.
Asphalt Cowboy Z1100R, 1981 Z1000J

phil churchett
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#2 PostAuthor: phil churchett » Wed Feb 10, 2010 8:29 pm

Carbs look superb Chris, just as a matter of interest, how many miles has the motor done?
Four pipes rule, anything else is second best.

Davy Doherty

#3 PostAuthor: Davy Doherty » Wed Feb 10, 2010 8:38 pm

Now shes broken down, ebay the parts :D that'll be another thou out of the way :shock:

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#4 PostAuthor: tlc » Wed Feb 10, 2010 8:38 pm

I take credit merely for the organisation SKILLS where the carbs are concerned Phil.

The engine has done 32k miles and it would seem that the extra 100cc makes all the difference as far as longevity is concerned :wink:
Asphalt Cowboy Z1100R, 1981 Z1000J

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#5 PostAuthor: tlc » Wed Feb 10, 2010 8:41 pm

Davy Doherty wrote:Now shes broken down, ebay the parts :D that'll be another thou out of the way :shock:


Davy, you gotta make it to a meet so as I can buy you a pint...........

































And tip it over your head :lol:
Asphalt Cowboy Z1100R, 1981 Z1000J

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#6 PostAuthor: Ginger Bear » Wed Feb 10, 2010 8:42 pm

Looking good Chris......
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Phil Churchett Award Winner 2011 & 2016 :D
Buzzworkz Best Modified Zed 2016

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#7 PostAuthor: GUYZED » Wed Feb 10, 2010 8:42 pm

Ditto what Phil said...the carbs look ace.
OLD ZED'S NEVER DIE THEY JUST GO FASTER...
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#8 PostAuthor: Pigford » Wed Feb 10, 2010 8:52 pm

Looks in fine fettle TLC - and the mixture appears pretty spot on, looking at the photo of the head with the plugs still fitted :wink:
And on the 7th day... Zeds were created!

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#9 PostAuthor: tlc » Wed Feb 10, 2010 8:59 pm

Cause it`s all standard Pig.

Centre stand and all :D
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#10 PostAuthor: mikey » Wed Feb 10, 2010 9:17 pm

Carbs look realy nice chris as im sure rest of bike will
Making the world a shiny place with a factory finish

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#11 PostAuthor: Steve S » Wed Feb 10, 2010 9:56 pm

Beautiful job so far Chris,I wondered what you were up to when i saw your post regarding vapour blasting,good luck with the rest of the rebuild its gonna look good! :D

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#12 PostAuthor: stephen parr » Thu Feb 11, 2010 12:14 am

Hope to see it at the 'Ace' in April Chris!! :wink:

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#13 PostAuthor: tlc » Thu Feb 11, 2010 9:44 am

I started pulling the engine down a good few weeks ago and as a result carefully stored parts in the loft.

It seems I forgot about the barrels and cam cover when I visited Doug Cox yesterday :oops:

Another trip to Reading for me then :roll:
Asphalt Cowboy Z1100R, 1981 Z1000J

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#14 PostAuthor: Steve S » Thu Feb 11, 2010 2:47 pm

OOps....i know how you feel Chris I,v been doing mine a couple of weeks and i have parts everywhere!!.......Hope wifey doesn,t notice the fuel tank in the wardrobe!! :roll:

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#15 PostAuthor: Steve Cooke » Thu Feb 11, 2010 4:29 pm

Chris I take it you are doing the whole lump and not just the top end like in the photos, if not I would get those crankcase apertures blocked up pronto.


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