Z1OwnersClub GB

Got another project a few weeks back, a Z1b that was a none runner. Its in pretty good nick really, original dated wheels, switches, swinging arm etc.
The tank is super clean to say its been stood. I bought it really for when the crappy weather comes, but i got a bit carried away with myself the other day, you know how it is, one bolt leads to another and so on.
The engine is in fine fettle. No broken studs or fins that i can see. Anyway this were i am at the moment.

Great basis!

getting harder to find like that ......looking forward to the thread

Good luck with the project

Started to strip the engine down this weekend, no major issues, no awkward bolts etc.
The gears look fine, but when the crank was removed i noticed some damage around one of the locating pins.
I had the same on my A4 engine although not quit as bad. It was exactly the same pin, the one directly inline with clutch drive gear.
I'm guessing that this is the one with the most stress on it with the engine under load??. In time its enlarged the hole and the pin just fell out.

Hi Wrigers
bad news, very bad news...but it can be solved.
The cracks can be welded but it will have to be done by a real craftsman who has the correct equipment and a lot of skills. I've been reading about it on the German forum where the same thing happened and it could be repaired.
They wrote that the cracks where enlarged with a dremel tool, laser welded and that afterwards the welds were cleaned. Afterwards the cranckcase was machined on a lathe and a new location pin installed.
I hope you can find the correct people to repair the damage. A few years ago the costs were about 350 Euro...
Good luck, I hope you can solve it.
Philippe

Thanks Philippe, im in no rush, holiday next then I'll do some enquiries and take it from there.
Still not sure why it only happenes on that pin though.

Hi Wrigers
it's one of the few weak points of the "bulletproof" engine...
The problem seems to be that only that pin limits, prevents, the movement from left to right of the cranckshaft. The problem starts with the pin becoming loose. When the pin isn't corrected and tightened the pressure on the cranckcase becomes higher and ultimately the aluminum starts to crack...
I have my information from the German forum, so don't crucify me if someone else knows another (better) reason...
GrtZ
Philippe

I'd be grinding the case out where the cracks are until all the aluminium is gone well below where the cracks are.

Then a good welder can build it back up, without trying to get into cracks or crevises, or welding with trapped oil (oh how welders moan about trapped oil!!!) and you know any pre-stressed material is removed.

I'm sure Phillipe meant similar, but trying to actually weld the cracks would be chasing your tail I think.

Then, your machinist is working in brand new aluminium.

I know people who can do this if you are stuck.

Thanks Mark.
I'm on my jollies next week, so I'll pick up were I left off when I come back. I might pm you then. Paul

Wrigers wrote:Thanks Mark.
I'm on my jollies next week, so I'll pick up were I left off when I come back. I might pm you then. Paul

You're welcome, it would be an interesting little project.

Enjoy your hols.

I'd recommend a call to dave at buzzworkz(07930-847648)to repair and probably explain the root of the problem too..club member too so you might get a good deal too. fingers crossed... mark

Yes Buzzard my head build on the A4. Did a sterling job and a nice fella.

Just thought I'd post a few pic's of the Z1b project i have had ongoing since last year.
It's coming together slowly but surely, I've tried to keep in as original as possible, re chromed a lot of the stuff, refurbed the switches and clocks etc.
Paintwork just back and a sterling job it is,no decals used it was all hand painted to the original colour.
Bit of fun, but spot the deliberate mistake with the bottom cranckcase, just noticed it prior to putting the two halves together. Bit of a senior moment there....
Thanks to Tony at Pit Stop bikes for welding the fork leg.

Nice work, good man Tony, he's doing a repair for me at the moment, he did a crack repair on a locating pin point on my z1000a1, did a belting job, who polished the engine , Steve Smethurst?