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Z650 refresh...

Work in Progress

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chrisNI
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#136 PostAuthor: chrisNI » Tue Aug 30, 2016 10:43 pm

MDM wrote:In the meantime, I popped over to see Keith at Nasty Paint in Birmingham to pick up my finished bodywork. Here's a sneaky peak...


Old School!!!! :D

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#137 PostAuthor: MDM » Tue Sep 13, 2016 6:59 pm

So I'm in the 'cleaning and bolting stuff on' phase, and I've refreshed the front brake master cylinder with new seals, piston etc, but the remote reservoir looks really manky. I read somewhere on the interwebs that you can get rid of the yellowing by soaking them in bleach, and here it is after I did just that...
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Yeah, still horrid and yellow... :-(
Anyone any ideas about how I can get it looking all spangly and new again?...
Z650/1100 turbo, GPz750 rolling resto, Z650 restomod

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#138 PostAuthor: MDM » Tue Sep 13, 2016 7:00 pm

And, in further Stuff Bolted On news...
Image
Although the clutch cover has to come back off to fit the clutch, and the ignition cover still needs to come off for the crank seal to be fitted (running Dyna 2000 I need to use a Z1100 ignition cover but need to find out what seal fits that and the GPz crank...)
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Re: Z650 refresh...

#139 PostAuthor: MDM » Wed Mar 22, 2017 9:52 am

Long time no post.
Because long time no work.
But getting back to it as time is running out between now and the TT...
So, after losing various parts in a house move last October, I did manage to find some bits that I thought were lost. Only now I come to actually start putting things back together I realise that I have lost more than I have found. Arse.
In the re-attachment of parts I have discovered that there is no way that the oil feed and return pipes to the electic Shurflo oil pump that feeds the turbo will fit if the pump is mounted above the swinging arm pivot. SO that is getting relocated to under the sump. It won't look as nice or as neat, but it solves a problem and gives me plenty of room to fit the fuel pump and have a nice clear return run for the oil drain from the turbo. No pics just now, but some soon.
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Re: Z650 refresh...

#140 PostAuthor: chrisNI » Wed Mar 22, 2017 5:55 pm

MDM wrote:So, after losing various parts in a house move last October, I did manage to find some bits that I thought were lost. Only now I come to actually start putting things back together I realise that I have lost more than I have found.


There are gnomes that live in dark corners of the garage that hide stuff to fuck with you... :git

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Re: Z650 refresh...

#141 PostAuthor: MDM » Tue Mar 28, 2017 9:21 am

After a 280 mile round trip I found some of the missing parts! So then did a bit...
Hosing plumbed in for the boost gauge - clock back bored out and fitted with a grommet to prevent chafing on the hose.
Spacer found for behind rear of drive sprocket as the sprocket was wobbling around by itself even after nut was tightened.
Clutch actuation gubbins found and fitted, and then taken off as it wasn't working - process repeated several times to no avail so I walked away before I started threatening it with the Big Hammer. I'll have to go back to that today...
Small steps, but steps nonetheless.
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Re: Z650 refresh...

#142 PostAuthor: MDM » Tue Mar 28, 2017 7:29 pm

Rear brake fluid reservoir fitted - well, one of those HRC hoses, not ideal, but neater than a remote reservoir like the ZXR master originally had, and it was cheap too...
Fuel pump half-fitted, fittings in with PTFE tape so things are now going back together properly rather than just being bolted in place.
But I can't find the rubber mounts for the tail unit, or the fuel tap...
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Re: Z650 refresh...

#143 PostAuthor: MDM » Thu Mar 30, 2017 12:31 pm

It's fighting me all the way...
Chain fitted, no problem. Rear wheel aligned and tightened up and...

... the chain is hitting the swinging arm brace! Okay, so it's only just kissing it, but it's enough that I'll need to take the grinder to the lovely shiny swinger...

And when the spindle is tightened the rear wheel is nipping up. Not sure why this could be, first off I thought it was the caliper hanger pushing against the 'arm, but I tweaked the torque arm so the hanger hung clear, and it's the same. I'll have a closer look when I take the wheel out to sort the 'arm. A bit odd as it was fine six months ago before I moved house...

Front brakes bled and they're binding on. Initially I thought it was the aftermarket lever not allowing the master cylinder piston to return fully, but it was the same with the standard lever. So it's either (both) calipers sticking, or the master cylinder sticking... deep joy.
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Re: Z650 refresh...

#144 PostAuthor: MDM » Thu Mar 30, 2017 12:33 pm

As a thought - the calipers are ThunderAce 'bluespots' running on cast iron discs that're rather thicker than the usual modern sports bike discs, and there's not much clearance even when the pistons are pushed right back into their bores - a possible problem, or not?
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Re: Z650 refresh...

#145 PostAuthor: warren3200gt » Thu Mar 30, 2017 12:34 pm

Can you not put a chain tensioner on it to lift the chain away from the swingarm?
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Re: Z650 refresh...

#146 PostAuthor: chrisNI » Thu Mar 30, 2017 7:48 pm

MDM wrote:As a thought - the calipers are ThunderAce 'bluespots' running on cast iron discs that're rather thicker than the usual modern sports bike discs, and there's not much clearance even when the pistons are pushed right back into their bores - a possible problem, or not?


Sounds likely - are they binding badly if it's just slightly they may bed in?

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Re: Z650 refresh...

#147 PostAuthor: MDM » Fri Mar 31, 2017 8:31 am

I whipped the calipers off and cleaned up around the pistons - one wasn't rising out of its bore, and all were pretty smeggy, although not scored or rusty or bubbled. Cleaned up they still stick, although nowhere near as badly, I reckon it's just the one caliper now, but I didn't get time to check...
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Re: Z650 refresh...

#148 PostAuthor: MDM » Fri Mar 31, 2017 8:32 am

warren3200gt wrote:Can you not put a chain tensioner on it to lift the chain away from the swingarm?

I did consider a tensioner of some kind, but that'd require more surgery to the swinging arm than a mere bit of grinder-induced 'clearancing' - I'd want it to be a bit more subtle than a bolt-on tensioning device ;-)
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Re: Z650 refresh...

#149 PostAuthor: warren3200gt » Fri Mar 31, 2017 9:28 am

There is one that is spring loaded and mounts off the swingarm spindle tube. You can hardly see it when fitted. But........... I can't remember where I saw it or who makes it!
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Re: Z650 refresh...

#150 PostAuthor: Ginger Bear » Fri Mar 31, 2017 5:23 pm

warren3200gt wrote:There is one that is spring loaded and mounts off the swingarm spindle tube. You can hardly see it when fitted. But........... I can't remember where I saw it or who makes it!


There ya go........... http://www.monstercraftsman.com/categories/Tensioners/
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