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anuvva bleedin' J

Work in Progress

Moderators: chrisu, paul doran, Taffus, KeithZ1R

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Al
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anuvva bleedin' J

#1 PostAuthor: Al » Tue Apr 01, 2014 9:26 pm

Thank you Stu Puddin, Paul Doran, London Calling, JB, Big Phil Moore, Taffus, Steve Wilson and many more for free parts, help and advice.

This bike was previously 'The Black Knight'.

Very cheesey but its where it started for me thankfully nitromors came to the rescue :D .

In the last ten years it has been the platform for; a touring bike, a weekend drag bike, sprinter and now track bike.
Not good at any of them, me or the bike but its been all that was asked and more and i have tried (and others too) to break it and it has refused to yield.
Even under extreme provocation.

This is a new chapter for me and just like trials and motocross i have found that track riding is not going to provide me with an income but i am addicted.

Summary follows because i have spent every spare second of the last six months re-working it and this is what has turned up.

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The rear light unit is just a lens screwed to the back plate. Back plate is a replica of the original in alloy but without the indicator holes. It weighs about a quarter as much as the steel item.

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I have changed the wheels, discs, calipers, spindle, springs and put valves into the forks. Discs are made to a pattern and the calipers are from Steve in Ireland. Not the greatest setup but the pads are a new type of Brembo race only compound and the previous discs in the J wheel would easily lock up if required so no problems stopping and hopefully now no more diving at the front end.

http://www.z1ownersclub.co.uk/forum/vie ... 50&start=0

Front tyre is now a 110 so had to get a wider front guard and retrospectively paint to match the bodywork.
Six months sitting at work but its done thanks Scotty.
Dumped the speedo and therefore the speedo drive and replaced with a solid spacer.
Bearings and spindle and internal spacers all machined Thanks Tony P.


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Ground clearance has been a real issue so have lifted the side stand. Raised the rear end but retained the Koni Dial-a-rides, by welding new 'bosses' to the swingarm, in front of the original ones which give another 15 - 20 mm lift.
Had to make yet another chainguard because every time i change something the old one does not fit. I had to move the chainguard mounts as well because of the new wider rear wheel and hub/sprocket/cushdrive arrangement together with a 5/8 off set front sprocket since the rear tyre is now 150.
It actually measures up at 160 though.
The rear wheel is still 18 inch but the tyre profile is 65 which is overall 1/2 inch smaller in diameter than the old J wheel with a 130 /90.

This week i have removed the extra inch of foam it had had previously for other purposes.
It made the seat very soft and difficult to get 'out of' and 'back into'
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Just replaced the bars for lower ones.
I played with clip-ons but they are not for me.
I have removed the speedo, fuel gauge, and odo leaving just the tacho. No real need for anything else.
Left hand switchgear has gone and this weekend so will the ignition switch / steering lock because it worries me that it might activate when going along in a hurry!!
Right hand switch gear will go soon too. When i have worked out how to hot-wire the ignition it will get a remote press starter.


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Unfortunately last week i bashed the top of the tank with the RHS switch and put a dent and deep gouge in it.
Basta8d. That made me go drilling and tapping after a certain Bear on here and i managed to get a controllable lockstop and have it adjustable.
Tank looks like shit now Basta*d again.
I have also ditched the front splitter and elected to go for two full length front hoses.
One less compression fitting and half a pound saved.
Made a retainer from the handle of and old stainless kitchen spatula.

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Made a sort of tail tidy.
i did have the Dyna 2000 in there but it got wet so now moved to on top of the battery.

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Ventilated the starter cover because it gets too hot when sitting between track sessions. Has been very embarrassing at times as well.
:oops:

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Cut and re-welded for the fourth time the link pipe.
The comment from the instructor i got to follow me round was that the exhaust and the side stand were 1/4 inch from the deck so i had to do something apart from lifting the back end.
Couldn't go any higher because the brake arm is in the way.
Mad a new hanger bracket and shortly it will get an even noisier baffle as there are two meets this year with 105dB limits :shock:
Have also put folding footrests on because the 'round' fixed pegs were too small to be comfortable and dodgy in corners. Fragile too i guess as they were alloy tube but luckily i never found that out.

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Heres' a close up of the forward mounts for the lower end of the rear shocks. It brings the rear shocks to the same mirrored angle of lean as the front forks so looks a little less 'laid down'.

Managed to get the rear disc skimmed thanks Bill (pegasus engineering) and will get it drilled to match more the front set i now have.
i will also get it reduced in diameter and make a better caliper carrier bracket than the standard one and probably replace the standard caliper whilst i'm there.

The blocks at the rear of the swingarm are now welded in so no need of the bolts that secure them.
This was partly done because the gap in the rear forks was a baggy fit for the rear wheel spindle and is now tight as a nuns' nasty.

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The alloy bits will get powder coated black as although i have replaced many things i really wanted to keep the original appearance of the bike even down to the stupid passenger grab rail. Dumb really but its either all or nothing and i was not ~ am not ready or capable to make a bike like Rob zed 1015's racer.
Last edited by Al on Thu Apr 03, 2014 7:49 pm, edited 1 time in total.
1981 J1

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#2 PostAuthor: garyd » Tue Apr 01, 2014 9:40 pm

Looking real peachy Al...and a cracking write up.

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#3 PostAuthor: Chris Riv » Tue Apr 01, 2014 9:59 pm

Thats a sweet looking bike, well done chap, lovely work.

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#4 PostAuthor: z1000puddin » Tue Apr 01, 2014 10:08 pm

Very very nice - Just luuuvvv them wheels.

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#5 PostAuthor: jphaynes669 » Wed Apr 02, 2014 5:53 am

Very nice job al,,, loving the astralites mate. :D
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#6 PostAuthor: Pigford » Wed Apr 02, 2014 6:33 am

Al, that is fookin' great lad :twisted:

How do you do those loverly fluted vents for the starter cover - LUSH :?:

So, what wheels has Fatty got on his Z1R now :lol:
And on the 7th day... Zeds were created!

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#7 PostAuthor: Ginger Bear » Wed Apr 02, 2014 6:34 am

Great read there Al. :up

I'll look forward to following your track progress this year. The bike looks stunning.
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#8 PostAuthor: sanderz » Wed Apr 02, 2014 12:54 pm

Top job there Al, bike looks top notch. :drool
Great write up - gives an insight into the many hours and hours of labour / tinkering / headaches / making changes which are so often over looked or not seen. :up
Wots up DOHC

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#9 PostAuthor: coldsummer » Wed Apr 02, 2014 6:30 pm

Thats a great job Al, the bike looks amazing. I'm in awe of your skill and stamina.

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#10 PostAuthor: Redbeard » Wed Apr 02, 2014 7:33 pm

Looks great Al, I like the hints of originality with some clever touches and fixes to issues. Chainguard is neat too, looks like it means business! So is it track time only or will it be on the road too in the daylight hours?

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#11 PostAuthor: Al » Thu Apr 03, 2014 8:26 pm

Thanks for the comments. Have seen all youre bikes i think one way or another so i feel honoured.
I have ammended the first post because i forgot to mention Steve Wilson. I bet there are others also :oops:

How do you do those loverly fluted vents for the starter cover

Somebody carelessly left the louvering tool set up in the fly press at work which i noticed as i was walking past with it in my hand :D

So, what wheels has Fatty got on his Z1R now

He's still got the Peter Williams wheel up front and rear is a fat Suzuki one i think.
My front came from another source.

So is it track time only or will it be on the road too in the daylight hours?


Its got no mot or tax no lights, horn, speedo, indicators, mirrors so i have had to test ride it on my own (errrrr) private roads.
May get it MOT'd late in the year see how time gets on.
If its anything like last year it wont be visiting 'Blind Magoo's MOT emporium.

One last thing i want to do to complete this thread follows.

My original shopping list from the end of 2013

Wheels
Wheel spacers etc
Folding footrests
Caliper bolts hex X4
7/8 straight bars now 31 inch
6mm internal petrol pipe
Chain
Front sprox
Rear sproc
Cush drive bushes
20 weight fork oil
Pair front brake hoses 38 inch centre to centre banjo
Swingarm bearings and sleeves
Larger oil cooler
10 weight rear shock oil
Wider front mudguard
Oil filters
Two tyres
5 wheel bearings
2 front discs
Fork springs
Front pads
Tank rear damper rubber
Fork oil seals
Fork lower copper o rings
Petrol tap repair kit
Front fork race tech valves
Vapour blast
Nuts and bolts 47
Stainless bar
Alloy tube and bar

My original jobs list from the same period:

Replace rubber front engine mounts with solid alloy
Lower faing brackets
Re-make fairing brackets
Modify swingarm shock mounts.
Cut swing arm for bigger tyre
Weld in rear security blocks
Repair holes in swingarm
Remove replace lower gusset plate of swingarm
Tap grease nipple into swingarm
move guard mounts on swingarm
Lift exhaust
Make new exhaust hanger
Lift side stand
Lower battery box
New wiring loom to make
Replace foot rest solid pegs
Spacers for front fot rests
Straight through baffle
Rebuilkd rear shox
Modify rear shox
Make chainguard
Cut re-weld exhaust
Alter rear mudguard extension
Grind and drill rear disc
Stoneguard for oil cooler
Heat resistant oil lines
Polish fork legs
Paint exhaust
Paint rear disc centre
New ignition switch
Replace plastic tube in front forks
Re-tap bolts for rear sprocket
Camera mount
Re-place bolts 5mm for fairing
Side stand clip
Narrow front brake pads
B9ES
DOT4

I bet you can guess what happened to both those lists :!:

Dont know how you get things done but this is me.
Most bits of paper are written on on both sides.

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Roll on 2014 and lets be careful out there.

AL
1981 J1

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#12 PostAuthor: Padders » Thu Apr 03, 2014 8:37 pm

Looks great Al a real credit to all your hard work. Have a great 2014 on her.
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#13 PostAuthor: jimmock » Thu Apr 03, 2014 11:08 pm

Yes indeed, a fine looking machine.
The wheels do look braw.
The bars put a new meaning to "flat bars" !!

I was also impressed with the gorgeous setting you have around your house.
Jimmock. :wnkr


SPEED IS JUST A QUESTION OF MONEY...HOW FAST DO 'YOU' WANT TO GO?

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#14 PostAuthor: jimmock » Thu Apr 03, 2014 11:10 pm

Yes indeed, a fine looking machine.
The wheels do look braw.
The bars put a new meaning to "flat bars" !!

I was also impressed with the gorgeous setting you have around your house.
Jimmock. :wnkr





SPEED IS JUST A QUESTION OF MONEY...HOW FAST DO 'YOU' WANT TO GO?



I hate people I don't like !

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#15 PostAuthor: jimmock » Thu Apr 03, 2014 11:12 pm

PC on the boat has a stutter!!!
Jimmock. :wnkr





SPEED IS JUST A QUESTION OF MONEY...HOW FAST DO 'YOU' WANT TO GO?



I hate people I don't like !


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