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Z1R - The Work Begins!

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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ted1r
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#31 PostAuthor: ted1r » Wed Jan 20, 2016 4:58 pm

Nice job and another to swell the ranks.

Ted
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Be careful with Pensions :eek

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bulldogbobby
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Re: Z1R - The Work Begins!

#32 PostAuthor: bulldogbobby » Sat May 13, 2017 2:09 am

IMG_2806.JPG

Almost ready to put the tank back on but the fuel sender unit doesn't seem to be working?
I'm assuming they work on a variable resistance but I've hooked a multimeter up to it and the readings are all over the place - I've also had it plugged into the loom and the fuel gauge doesn't move when I move the sender float. Anyone have a working one they'd be happy to sell or know of a test procedure?

Seems my only other option is a new Doremi unit but I'm not too sure if they're any good?

Mine was definitely working when I took it out a few years ago!
(Believe it's Part code 52005-1002)

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Let The Good Times Roll...........

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KeithZ1R
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Re: Z1R - The Work Begins!

#33 PostAuthor: KeithZ1R » Sat May 13, 2017 9:06 am

Looking good Andy :up , see you have elected to keep the american lighting control wiring. So out of curiosity what does exactly it do ? none of mine ever worked due to earlier butchering. As for the sender careful bending of the tangs will allow you to remove the cover on the rheostat and you could try cleaning up the coil winding
Keith
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bulldogbobby
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Re: Z1R - The Work Begins!

#34 PostAuthor: bulldogbobby » Sun May 14, 2017 4:09 am

Hi Keith,

Eagle-eyed as always! Not 100% sure but think the only real difference with US wiring is the reserve lighting system? (i.e. keeps the headlight and rear light on if one of the filaments burn out) and the lights should be switched on when the ignition switch is turned on? (mine doesn't do this so may have been modded?)
Thanks for the fuel sender info

Cheers,

Andy
Let The Good Times Roll...........

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Re: Z1R - The Work Begins!

#35 PostAuthor: bulldogbobby » Mon Jun 04, 2018 4:05 pm

Haven't been able to do much on the bike over the past few months and hit a bit of a wall with progress once I got back to working on it - couldn't get any fluid through to the rear caliper (I'd thoroughly cleaned everything, replaced all master cylinder and caliper internals and fitting a new brake hose). After trying everything else, I finally sorted it by...................... stripping the master cylinder (again!) and cleaning out the two holes under the side bolt (supply and relief ports?).
Rear Master Cylinder Stripped.JPG


Rear caliper was stripped again and everything was rechecked
Rear Caliper Stripped (Before Reassembly).JPG


After reassembly, fluid was bled through with a Mityvac and brake seems spot on now - pretty much everything changed for new and the pipe's back on!. On the home straight!
Brakes Done - Exhaust Silencer Fitted.JPG
Let The Good Times Roll...........

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Re: Z1R - The Work Begins!

#36 PostAuthor: DavidZ1R » Mon Jun 04, 2018 7:57 pm

bulldogbobby wrote:Hi Keith,

Eagle-eyed as always! Not 100% sure but think the only real difference with US wiring is the reserve lighting system? (i.e. keeps the headlight and rear light on if one of the filaments burn out) and the lights should be switched on when the ignition switch is turned on? (mine doesn't do this so may have been modded?)
Thanks for the fuel sender info

Cheers,

Andy


Also on the American model the indicators on the front are wired to have a permanent light on.
CB125 GT380 CB750F1 Z1R GPZ 750 Turbo Z1R

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bulldogbobby
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Re: Z1R - The Work Begins!

#37 PostAuthor: bulldogbobby » Tue Jun 05, 2018 12:33 pm

Also on the American model the indicators on the front are wired to have a permanent light on.[/quote]

Mine must be 'UK' spec - indicators are wired as normal :up
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Re: Z1R - The Work Begins!

#38 PostAuthor: KeithZ1R » Tue Jun 05, 2018 2:02 pm

bulldogbobby wrote:Also on the American model the indicators on the front are wired to have a permanent light on.

Mine must be 'UK' spec - indicators are wired as normal :up


Stateside/Canadian models had three wire indicators and dual filament bulbs
Keith
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Re: Z1R - The Work Begins!

#39 PostAuthor: pertonpc » Tue Jun 05, 2018 10:41 pm

I had a doremi fuel sender unit.

Worked fine but the shroud is hard plastic ( not soft rubber like original) and it showed underneath the tank slightly if fitted.

Think the factory shroud will fit if you still have a decent one.

Have some pics if needed.
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Re: Z1R - The Work Begins!

#40 PostAuthor: PAULJAC47 » Wed Jun 06, 2018 8:03 am

Nice work,credit to you!
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Re: Z1R - The Work Begins!

#41 PostAuthor: Graham-A2 » Wed Jun 06, 2018 2:19 pm

Lovely job - really good looking Z1R too.

Curious about your rear brake reservoir rebuild as I have one on the bench at the minute that's resisting me a little. The reservoir is pretty old and gungy and I'm struggling to get the piston out under the reservoir. It's presently sitting upside down and had a good dowsing of penetrating oil all over the piston (hopefully getting down the bore. Is there a trick to remove / unseize? I also didn't spot that the plastic discs at the bottom of the reservoir come out.... do these unscrew or just need gentle persuasion ? Can't remember to manual being too useful when I last looked.
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Re: Z1R - The Work Begins!

#42 PostAuthor: bulldogbobby » Fri Jun 08, 2018 8:57 am

Graham-A2 wrote:Lovely job - really good looking Z1R too.

Curious about your rear brake reservoir rebuild as I have one on the bench at the minute that's resisting me a little. The reservoir is pretty old and gungy and I'm struggling to get the piston out under the reservoir. It's presently sitting upside down and had a good dowsing of penetrating oil all over the piston (hopefully getting down the bore. Is there a trick to remove / unseize? I also didn't spot that the plastic discs at the bottom of the reservoir come out.... do these unscrew or just need gentle persuasion ? Can't remember to manual being too useful when I last looked.


I had the same problem with the piston - mine was stuck fast but I got it out by drilling and tapping it.
Rear Master Cylinder Threaded Piston.JPG


Rear Master Cylinder - Old Piston.JPG



Rear Master Cylinder (Old Piston ).JPG


You've probably got this already?


Rear Brake Schematic.JPG


The plastic disc is held into the reservoir by small plastic tabs - just lever them out of the body (gently!) - Good Luck!
Let The Good Times Roll...........

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Re: Z1R - The Work Begins!

#43 PostAuthor: Graham-A2 » Fri Jun 08, 2018 9:10 am

Brilliant - thank you, that is certainly the sort of solution I think I need. That piston seizes well in there doesn't it !

Thanks also on the strip out of the discs from the reservoir cup. I was thinking of this just to make sure that I thoroughly cleaning any crud out of there. Will probably review once I shift that piston out and see if I actually have a problem. Looks easy enough with care, hadn't spotted the plastic tabs keeping it all together.

Many thanks for the help Bobby
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Re: Z1R - The Work Begins!

#44 PostAuthor: bulldogbobby » Fri Jun 08, 2018 9:14 am

Graham-A2 wrote:Brilliant - thank you, that is certainly the sort of solution I think I need. That piston seizes well in there doesn't it !

Thanks also on the strip out of the discs from the reservoir cup. I was thinking of this just to make sure that I thoroughly cleaning any crud out of there. Will probably review once I shift that piston out and see if I actually have a problem. Looks easy enough with care, hadn't spotted the plastic tabs keeping it all together.

Many thanks for the help Bobby


No probs mate - just remember to clean out the two holes under the side bolt (think one is the supply port and the other (smaller) one is the relief port. I cleaned mine out with a set of safety pins I bought from my local hardware shop for a quid - after trying wire brush bristles and cable strands, that worked a treat! Good Luck
Let The Good Times Roll...........


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