Z650 refresh...

[MDM]

So, the cheapo Aldi-bought Dremel copy got some action...
although this does mean that I'll now have to check out the welds on the inside of the up-pipe joining headers to turbo as well now. The amount of difference it'll make, performance wise, is totally negligible, but it makes me happy doing it...

[Pigford]

You can also engrave your name, once finished

[MDM]

I pulled out the standard battery box to see how much room I was going to have to fit a new (larger) battery.


And then went for a wander around t'interweb to see what kind of battery would suit my needs. I wanted a bigger battery as the standard acid battery (as per the original Z650) wasn't really man enough for the 1100 engine when I ran it before, it'd kick back on the starter, so I wanted something that not only had the potential to spin the starter a bit faster, for a bit longer, but also one that would have no issues with continually running the oil pump I'm going to use to lubricate the turbo. And that oil pump was (temporarily) mounted here...



Although I'm starting to think twice about it sitting there, given that I have to fit the oil tank somewhere as well, in a place that the turbo oil can drain into it efficiently...

[Big Fluff]

C'mon Dave, pull yer ruddy finger out, it's been 4 weeks since your last update

[MDM]

Yeah Will, I know, I know... ahem.
Been busy with writing etc, but hopefully back to it now, should have some spare time over Chrimbo to get properly stuck in. Got a battery, and aluminium to make new battery box, oil cooler bracketry etc...

[MDM]

I'd had a look at various battery sizes on line and, having chosen one with a nice fat output, decided to mock up a cardboard version to see if it's fit. Although it didn't go according to plan at the first attempt...

Fortunately, the second one was a bit better, so I could see how well it would fit, firstly longitudinally...

Which, quite clearly, wasn't going to work, so I tried it crossways...

Which is better, but it's clear that it could only go so far forward between the frame rails, and that the plastic mudguard (one of the few original Z650 parts) would have to be altered.

[MDM]

Oh, and while I remember, I have a Dyna 200 ignition for this bike. Well, I have all the Dyna kit apart from the actual Dyna 200 box itself. So I have loom, coils, ignition backing plate but need the box itself. I know that the newer boxes have a programmable function and can be plugged into a laptop, does anyone know if I can buy just the programmable box rather than a full kit?

[Ginger Bear]

Try Jeff at Z1 Enterprises. He recently supplied me a Dyna 2000 loom.

[MDM]

Thanks GB, I'll give Jeff a try. I've now heard that it is possible to buy the latest Dyna 200 module (the programmable one) as an upgrade from Dynatek, so fingers crossed

[Pigford]

I have a spare Dyna 2000 box - working .... if any good

[MDM]

PM heading your way Mr Ford

[Big Fluff]

Maybe your ignition was a tad too far advanced if it was kicking back. I use the standard Z1 size battery, the AMG battery from wemoto.
Mines fine at 37 degress btdc, always has been.
After the wastegate failure and blow up, I'm now calling up 4 degrees of retard at 5psi and dumping at 7psi.

[MDM]

It was running a Dyna S at the time Will, and always span over a bit slow on the starter. So, Dyna 2000 for boost retard, big battery and CB900 starter motor for a bit more spin should see any potential issues dealt with. once it's got a decent wiring loom of course ahem

[MDM]

I managed to get a second-hand Dyna 2000 (many thanks to Pigford for that!), so that's been stashed somewhere safe while I carry on with the battery box.
The battery turned out to actually be pretty close to the cardboard dummy that made, which was surely luck and/or coincidence more than my accuracy with cardboard.

So after some judicious measuring of the frame area and the original steel battery box, I chopped up some more cardboard and made a faux battery box before I started cutting aluminium. as the new battery is wider (and taller) than the original, it's going to have to sit further back in the frame so, as I want to use the standard battery box mounting points, there was going to have to be a certain amount of offset in the box. which is why the cardboard one is too big from front to rear.

And sliding the carboard battery box between the frame rails shows that some of the plastic rear mudguard / undertray thingy is going to have to be cut out to allow it to fit.

Now to go and cut some 3mm aluminium...

[MDM]

Ally cut to size / shape and put in the el cheapo folder that I had stashed under the bench...

And tried for size in the frame. Quite clear that the rear mudguard needs to be relieved...

So it was marked up thus

And with the help of Charlie Dog, my faithful workshop companion...

... had a chuffin great hole hacked in it, using my Dremel-a-like and rotary saw blade.

Although the saw did take a liking to a finger too. It's tasted blood now...

And a trial fit showed that a bit more had to come out.