Z1OwnersClub GB

Hi guys
some of you will remember that I bought a wreck of a Z1B at the end of januari this year.
The past months I was involved in the restoration of a KZ1000Police and this project is nearly finished.
In the mean time I started today a new project, the restoration of my Z1B.
I invite you all to join me on the long way from start to finish.
For those who haven't seen the pictures of the wreck I bought here are a few.


as you can see there will be a lot of work to do but nothing I can't handle



I have a few Z900 cylinderheads which are complete, so if this one can't be saved, I 'll take a spare one



As you can see the rear mudguard was chopped off, it was far beyond the point of repair anyway, it was really rotten.



completely rotten but there were still a few square inches of chrome...



A new front mudguard is needed, this one is allso beyond repair.



In the past someone cut the lampholders to put clip-ons on ...



As you can see, the tank rubbers were gone and the previous owner used an old inner tube to dampen the fuel tank, it's a strange world isn't it ?



So this is the actual situation, perhaps more pictures of my new discoveries tomorrow.
Greetings from Belgium
Philippe

thats going to be a good project

Watching with interest - keep the good work & photo's coming!!!

Will watch with interest. Plenty of scope for improvement.

Wow phillipe you amaze me again if anyone can do it you can

Hi Derek

you won't believe it, it did worse than that...
GrtZ
Philippe

Hi Guys

continued the "demolition" on the Z1B today
Here are some more pics, enjoy them


I stripped allmost everything from the frame to take the engine out.
I allso dismounted the camshafts to get a bit more clearance between the engine and the frame and I laid it down on its right hand side.

A few minutes later this was the result


I'll disassemble the engine later this week to see what is inside
In the mean time I tried to create a bit of order in the chaos after the disassembly and stored several parts in boxes to make an inventory of what I have and what is missing.
I allso collected several parts to use from my stockpile and this is the result


All these and a lot more will become a Z1B. When will it be finished ?...I don't know, time will tell.
Greetings from Belgium
Philippe

Top work especially engine removal

Hi guys

did some work during the past few days, on the engine and on the frame.
I'll start with the engine:
It was taken apart completely, first the head came off then all the remaining engine covers and finally the cylinderbank.
After that I removed the pistons and then it was time to split the cranckcase.
All the inner parts were putted in boxes, to keep them "clean" and to avoid them to become rusty from the moisture in the air...
At the end of the day I started to degrease the upper cranckcase.

I use thinner to degrease it, and I do that outside, if not I become "high" from the vapours of the thinner...
That was yesterday.

Today I decided to give a bit of attention to the frame.
There were parts and nuts added, holes made where there aren't supposed to be, parts grinded off and one "ear" on the left hand side was twisted and deformed.



SET THE GRINDER ON IT

The result of 10 minutes grinding
After that job it was time to clean up the frame

Another 30 minutes of work gave these results




There were a few holes in the frametubes where there aren't supposed to be so they had to be closed

I used an old damaged bolt to screw in the hole, the bolt is an M10x1,25 and was used to secure the engine in the frame. Someone used an M10x1,5 nut and damaged the thread. I couldn't repare the thread so I used the bolt for filling op the hole. Never throw anything away, you might need it someday!

The tools I use are simple : see for yourself.

That's really all it takes and a bit of work and patience.
The next part will be the repair of the "ear" at the back left hand side.
GrtZ
Philippe

I'm back and the story continues...
The "ear" at the left hand side was deformed. I think someone in the past crashed the bike causing the damage.
It's important that the"ear" is rather straight in order to position the indicator in a decent way.

The indicator rubber was trapped between the inner and the outer metal part and it was neccesary to remove it before I could heat the metal.
After a bit of hammering the metal gave way and the remains of the indictor rubber were removed. Now it was time
to heat the metal in order to get it straight and more or less into the correct shape
After heating and hammering a few hours I was pleased with the results, see for yourself


Once again simple tools and a gastorch, not a sophisticated one, no just keep it simple


The swing arm allso caused a bit of a problem...the two bolts of the small parts at the end were both rusted solid with the swing arm and snapped off.

I decided to cut the small steel parts in half, remove one part and then I could remove the other half to expose the remains of the bolt.

After that it was a matter of WD40, a bit of time and a pair of pliers

So far, so good.
Oh, I forget to say that I have a spare pare of those little parts to put in the swing arm...the ones I removed can't be reused.
I chose that drastic way in order to avoid damage to the tread in the swingarm.
Tomorrow more news about the repairs on the frame, the making and welding of the missing parts...
To be continued...
GrtZ
Philippe

Good work Philippe you’re steaming ahead..

Top work philippe

Keep the pics coming Philippe, great job, love it.

Hi guys
a few days later than I promised but here's the next episode;
As you noticed there were parts of the frame missing : at the right hand side someone cutted off the holder for the rubber dampers of the exhaust. Not a nice sight ...

On the left hand side they allso decided that the "tube" of the seat lock was in the way of the home made locking device so it was removed...

Since I'm not that good in bending and shaping metal I used steel tubes to fabricate the missing parts ...

I only had to weld those on the frame, I never had any technical education but learned it all by trial and error and now, after many years, I succeed in welding two metal parts together ...

Allmost ready, it just needs a slot to get the mechanism in and the mechanism itself, but that's a detail...
Originally it was made of a steel plate which was bend . A Z1 owner can see it for himself, at the underside of it you can notice the seam. I had to use a piece of steel tubing with holes drilled in and smoothed edges.
I took an M6 bolt to secure it into place before welding it on the frame.

The missing part consists of two pieces, one to elongate the frame tube and another to recieve the rubber dampers.
I welded the frame tube first so I could clean up the weld without risking damage to the damper holder.
This will do the job!
Just notice that I even succeed in reproducing the "splatter" that was common on the frames of that era
Next time some work on the cleaning of the engine parts.
GrtZ
Philippe

Hi guys
as promised some pictures of the engine cleaning.
I allready posted a picture of the upper cranckcase...

I did some work on it and it looks quite clean now. See for yourself...

No sandblasting, only rotating nylon brushes and a lot of elbow grease.
The studs are cleaned, degreased and painted with heat resistant paint. Not the two on each side because these get in the oil channel, no paint on those!
The other engine parts will get the same treatment.
During the disassembly of the engine I discovered some nice and some bad surprises, as usual...

The original metal plate was still there. Most of the time these are gone.
As a bonus I found out that the two little chromed bolts that keep the chrome cover of the starter motor in place, were used to bolt the plate to the sprocket cover.

There was allso a nasty surprise ...
Sometime in the past the oil drain bolt must have been stuck in the sump, someone banged on it with a hammer to loosen it but that resulted in a crack in the sump.
They had to dismount the oil sump and weld the crack in order to use it again.


You can see the place where they've put the chisel, it not only took a bit out of the oil sump but it allso made a crack in it.
I have some spare parts so I'll use another oil sump and replace the welded one.
When disassembling the engine I found out that the pistons were rather clean. Mostly there's a thick layer of soot on them, not difficult to remove but sometimes it gives an indication of the state of the valve oil seals and of the wear of the valves and valve guides.


Anyway, I allways replace the oil seals and clean the valves when I reassemble an engine. The valves are allways checked to see if they're not bend and grinded in the valve seats to assure a good fitting and sealing.
When the valve guides are worn out, they're replaced with new ones. That's done by a professional! I don't have the tools or the equipment...or the skills to do it.
Since I'm back to work things will take a bit longer.
Next time some more news of the preparation of the frame prior to painting.
Tada
GrtZ
Philippe