Z1OwnersClub GB

Nice job and another to swell the ranks.

Ted

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)

Cheers

Looking good Andy , 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

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

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 caliper was stripped again and everything was rechecked


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!

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.

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

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

Stateside/Canadian models had three wire indicators and dual filament bulbs

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.

Nice work,credit to you!

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.

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.







You've probably got this already?




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

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

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

Well, it's taken me a while but I finally got there!

Apart from a couple of minor cosmetic bits, the Z1R's finally finished and I've had a brilliant Summer on it!
I've always 'tinkered' with bikes in the past and had a (relatively small) bit of mechanical knowledge but never attempted anything at all like this and after my first post , it's fair to say it's definitely been a very steep learning curve!

I don't post on here too often but the knowledge and information gained from this site has been invaluable so thanks to all that have helped along the way. Got plenty of pics of the bike at various stages of the rebuild and didn't know what to put on here so attached a few of the 'finished' bike. Anybody want any more - just let me know.

There were plenty of times when things didn't go the way I wanted them to but all I'd say to anybody else in a similar position to me when I started is take your time, take pics of everything and go for it! If I can do it - anybody can