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Z1000A1 - Basket Case Build

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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csx355
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Re: Z1000A1 - Basket Case Build

#31 PostAuthor: csx355 » Mon Dec 18, 2017 12:35 pm

After the Valve stem / spring seat fiasco I had the luxury of an entire day in the garage yesterday and once the head was on it seemed rude not to size up the logistics of fitting the motor in the frame. So with the frame and forks secure on a mobile scissor jack, protected by push bike inner tubes and the motor suspended with 3 x 1" ratchet strapping and scaffold pipes from the rafters all it took was some minor adjustment on the height and angles and boom! In she goes. Now she's beginning to look like a proper bike! I will try and get some pics up because obviously without them it didn't happen. But FWIW you can fit a Z motor solo without dropping a bollock. Bonus is I now have some room in the garage for the CB550 that should be winging it's way to me. Just don't know what to do with the RD250C that fell in my lap on Saturday!! ;-)

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Re: Z1000A1 - Basket Case Build

#32 PostAuthor: glav666 » Mon Dec 18, 2017 7:26 pm

Keep up the good work, your almost there, more pics please.
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Re: Z1000A1 - Basket Case Build

#33 PostAuthor: csx355 » Mon Dec 18, 2017 7:58 pm

more pics please.


I know, I know - I have been slack on the picture side - Tonight the shallow side of me decide that a little dressing up might be in order.

Pics as requested

IMG_0021.jpg
IMG_0022.jpg
IMG_0020.jpg
IMG_0017.jpg
IMG_0018.jpg
IMG_0019.jpg


Yes I know - I'm going to sort the shox out but they were available at the right time and right price, and I was grateful for them.

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Re: Z1000A1 - Basket Case Build

#34 PostAuthor: Pigford » Mon Dec 18, 2017 8:05 pm

Looks good - but doesn't look overly secure on the stand :??
And on the 7th day... Zeds were created!

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Re: Z1000A1 - Basket Case Build

#35 PostAuthor: csx355 » Mon Dec 18, 2017 8:52 pm

Where's your sense of adventure Piggy? -

Seriously though you are right it's just that I started with the bare frame on the scissor jack, and I have yet to build the wheels - mainly because at the moment I don't have a rear hub - anyone?

Got to say Piggy - your Avatar is the best on the net - every time I see it it makes me smile - never seen pork so enthusiastic - especially at Christmas!!

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Re: Z1000A1 - Basket Case Build

#36 PostAuthor: ADRIAN H » Wed Dec 20, 2017 7:40 pm

I have a rear hub, but unsure of condition ? Will pm some pictures hopefully tomorrow.
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Re: Z1000A1 - Basket Case Build

#37 PostAuthor: ADRIAN H » Thu Dec 21, 2017 7:58 pm

Hub is Powder coated - which if you wish your bike to standard will not be of use for you. Slight damage to bearing housing disc side where bearing has been prised out.
Suspect it has been powder coated as the chrome spoke rim needed to be rechromed.

Have sent a pm, but it will only let me send one picture.
Attachments
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Re: Z1000A1 - Basket Case Build

#38 PostAuthor: csx355 » Fri Dec 22, 2017 7:56 am

That's very kind of you Adrian - the story so far is that the steel spoke flange on my original hub had all but dissolved with rust.
IMG_0062.JPG
I had the bare hub body vapour blasted with a view to getting a new flange made. I dropped it into a local engineering shop about four months ago who assured me that they could press off the flange and make a replacement. They removed the flange but to date still have not made the flange. To be fair to them I was not in a hurry as I was building the rest of the bike. I kept in touch and the latest is that I should get the finished article next Thursday. Sooo - if that happens and all is well I'm good to go, however if not could I have first dibs on yours please?

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Re: Z1000A1 - Basket Case Build

#39 PostAuthor: Mr Bump » Fri Dec 22, 2017 8:14 am

csx355 wrote:Whoops - I seem to have acquired a gentleman's inconvenience!
IMG_0154.jpgIMG_0158.jpgIMG_0157.jpgIMG_0156.jpgIMG_0159.jpg

Picked these up this morning from Justin at Mark Skinner auto-bodies. The colour is Mazda Noble Green. It has a deep metallic fleck, and depending on the light conditions the colour appears to range from deep metallic blue, reptilian iridescent green to a classy rich purple.

Any way I'm just off to mop up!


Nice apples too.
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Re: Z1000A1 - Basket Case Build

#40 PostAuthor: ADRIAN H » Fri Dec 22, 2017 10:58 am

csx355 wrote:That's very kind of you Adrian. I kept in touch and the latest is that I should get the finished article next Thursday. Sooo - if that happens and all is well I'm good to go, however if not could I have first dibs on yours please?


No worries, just let me know either way.
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Re: Z1000A1 - Basket Case Build

#41 PostAuthor: csx355 » Fri Dec 29, 2017 2:09 pm

No worries, just let me know either way.

Hi Adrian - just rang my guy - he reckons Friday next week!! Personally I'm not convinced - I've pm'd you ref your hub.

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Re: Z1000A1 - Basket Case Build

#42 PostAuthor: ADRIAN H » Sat Dec 30, 2017 7:49 pm

csx355 wrote:
No worries, just let me know either way.

Hi Adrian - just rang my guy - he reckons Friday next week!! Personally I'm not convinced - I've pm'd you ref your hub.

Rear hub will be in the post to you next week.
Fingers crossed the chap can replicate the spoke rim.
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Re: Z1000A1 - Basket Case Build

#43 PostAuthor: csx355 » Wed Jan 03, 2018 6:26 pm

Good day today - been struggling a bit with the electrics but thanks to some help and advice from forum members it's job done! -

Many thanks Philippe and Paul - I was going around in circles for an hour or so today so I started from scratch at the battery and followed the starter motor wiring through the HT circuit and then the LT circuit through the Ignition switch and the starter button. This was a relatively easy process even for me to follow. Once this was sorted the rest of the system just lit up.

The motor turns on the starter nicely but I did have the left flasher indicator lamp light up when I pressed the headlamp flash / pass switch which took a little thinking about. Then I figured that I had just put the bulb holder in the wrong hole - quick swap about and we are fully lit in the correct places. Other than that I have rear light - brake light - indicator indicators - just no indicators at the moment!!

I have got a new set of indicators on the way as I only have two rear lamps of dubious origins - when they arrive I will be able to fit the headlamp. Then static time the bike - there is an electronic ignition system on it that I need to identify and get my head around. Next job will be building the wheels - hopefully I will have the original refurbed rear hub to work with but if not Adrian has given me a viable contingency option. Thank you very much.

Fit the carbs, air box, tank, panels, seat, grab rail - better get one - wheels, calipers, tyres, centre stand and foot pegs and we are pretty much done. Should only be a month or so :-)

I am going to go with the original (with the bike) Harris exhaust for the moment. If I feel the bike is a blinder I will try and get a replica 4 into 2 made and spend out on some other 'snagging' finishing touches as I see fit. 4 into 2 going spare any body??

One thing I do need to do is make some decent coloured windows for the Idiot lights - the binnacle itself is good but the clear coloured windows are foggy and nasty. Any ideas what I can use?

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Re: Z1000A1 - Basket Case Build

#44 PostAuthor: csx355 » Tue Jan 09, 2018 10:08 am

Rear wheel built thanks to Adrian H - just going to start on the front and with a fair wind she might be on her rubber tomorrow!
IMG_4768.JPG
IMG_4767.JPG


Weird - the pics are displaying 90' out until you click on them.

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Re: Z1000A1 - Basket Case Build

#45 PostAuthor: csx355 » Tue Jan 09, 2018 3:58 pm

IMG_4769.JPG


Happy with that - two stainless rims laced, tension'ed, trued and ready to go. Snuck them through under the radar at work!

Day off tomorrow so fit the tyres and tubes and take the weight off the stand. Carbs stripped, ultrasonically cleaned, jetted rebuilt and polished (to a reasonable degree honest Kev). Might even get them fitted up tomorrow.

Bike's main harness is all spanky and new and I have stripped, vapour blasted and re-anodised the switch gear housings, repainted the lettering and refurbed the contacts and harness's.

Headlamp and indicators all fitted up and original horn tidied up and fitted. Everything even seems to works when the appropriate buttons are pressed, even the starter motor. It's almost emotional hearing the motor spin over for the first time in 20 odd years.

Calipers have been professionally re-furbed - just cant remember if I have any pads for them. -

So loads of bitty stuff still to do but we are getting there.


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