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Z1R Resurrection

Work in Progress

Moderators: chrisu, paul doran, Taffus, KeithZ1R

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The Living Zed
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Location: Cannock, South Staffs

Z1R Resurrection

#1 PostAuthor: The Living Zed » Wed Dec 05, 2018 9:01 pm

Z1R Resurrection
Hello All,
I bought my Z1R back November 1989. I swapped for my SR650 and £500.
It was Moriwaki tuned and was pretty quick. At first I thought the clutch was slipping cus the rev's went up with a twist of the throttle without any extra forward movement.
Then I realised it was wheel spin as I went passed a car and started broadsiding, not a knackered clutch. It was November and the roads were a bit slippery, so that didn't help.
About a year later some t**t in an XR3 hit me. I was U turning outside my mates. I looked, as you do, nothing coming, so turned round. Next thing I know I'm in Hospital.
At the scene the car skidded for 25 metres and knocked my bike 22 meters up the road. I bounced off the wind screen. They found fibre glass from my helmet in it and the roof was all bent so the car was a write off. All I had was a broken ankle and a head ache and a broken Zed. I recovered and fixed the Zed which wasn't too bad really. New swing arm, rear foot hanger tubes and points and cover. It did have Dyna ignition but that got smashed, so I put points on it. The rest was cosmetic
The accident investigators blocked the road some time later to simulate the accident and they reckon the XR3 was doing over 70 mph.

A brilliant bike. Loved every mile. I'd been running it with bell mouths on though and no air filters. Big mistake. Bell mouths stop bumble bees getting sucked in but abrasive dust took its toll.
It started smoking, which is a filthy habit. It was 1996 and I'd just finished building my other bike so I took the Zed off the road with every intention of repairing it, so I dismantled it and stashed all the parts carefully. The cylinder head was quite bad. Fins broke off from the accident and tappet clearances on minimum.
As life continued, my journey through it didn't give me the opportunity to work on the Zed. When we moved house my mate stored the Zed for a few years, then I got it back, but still didn't do anything to it. My daughter started university in 2016 for 3 years and I thought "Right! That's it. I'm gonna do the Zed before she finishes uni". It was great going through all the bits. I'm glad I stashed it all so well. You know how these things go. There’s a vital part or parts missing that would put extra expense on the project, but I'd got everything.
I was playing in a band which took a lot of my spare time and was one of the reasons it took me so long to get round to the project. The first thing I decided to work on was the carb’s. Back in 97 I’d stripped ‘em down cus the Zed had stood with fuel left in it for a while before I dismantled the bike. The petrol had evaporated and left a kind of lacquer residue behind, so I’d started cleaning them up but that’s as far as I’d got. Fast forward to 2016. I like carburettors. They’re nice to mess with. I managed to clean all the nasty off and got em back together and they look great. I just hope they work as good as they look. Mind you, all the carbs I’ve ever messed with, I find that as long as they’re all clean and nothing obviously worn out they work. I even balanced them. I come across this somewhere. Get 4 ball bearings Ø3 or Ø4 and put them in the intake against the slide. As you raise the slide slowly with the tick over screw, the ball bearings drop through. . Adjust the slides so that your balls drop simultaneously when the slides open. I know each cylinder sucks different, but it’s got to be a good starting point from a rebuild. Oh yeh! DON’T do this with carbs on the engine. You don’t want balls in your head.
Attachments
IMAG0915.jpg
IMAG0912.jpg
IMAG0907.jpg

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The Living Zed
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Location: Cannock, South Staffs

Re: Z1R Resurrection

#2 PostAuthor: The Living Zed » Wed Dec 05, 2018 10:06 pm

Next up - Cylinder Head
IMAG0203.jpg
IMAG0232.jpg
IMAG0236.jpg

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The Living Zed
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Location: Cannock, South Staffs

Re: Z1R Resurrection

#3 PostAuthor: The Living Zed » Wed Dec 05, 2018 10:11 pm

Bob the welder did the fins.
I cleaned up the valves and checked them on a shadow graph
Attachments
IMAG0276.jpg

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The Living Zed
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Re: Z1R Resurrection

#4 PostAuthor: The Living Zed » Wed Dec 05, 2018 10:16 pm

The guy on the wire eroder at work made me a valve seat cutter - 3 angle job
IMAG0281.jpg
IMAG0300.jpg
IMAG0302.jpg

Got em all blued in nice.

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The Living Zed
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Re: Z1R Resurrection

#5 PostAuthor: The Living Zed » Wed Dec 05, 2018 10:22 pm

Barrels next. Nasty score (like Wolves 0 - Huddersfield 2)
IMAG0216.jpg

Already on top limit so only 1 thing to do. New liners

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The Living Zed
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Re: Z1R Resurrection

#6 PostAuthor: The Living Zed » Wed Dec 05, 2018 10:27 pm

The old liners came out quite easily with a flat block of wood and a mallet
IMAG0677.jpg

Then I checked to make sure the bores were square to the base and got sizes for the new liners

cakeman
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Re: Z1R Resurrection

#7 PostAuthor: cakeman » Wed Dec 05, 2018 10:39 pm

Liking this a lot :D I'm just up the road from you in Rugeley....and yes Huddersfield was nasty but Chelsea was better :lol:

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The Living Zed
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Re: Z1R Resurrection

#8 PostAuthor: The Living Zed » Wed Dec 05, 2018 10:51 pm

Thank you very much. I got loads more to publish

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The Living Zed
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Re: Z1R Resurrection

#9 PostAuthor: The Living Zed » Wed Dec 05, 2018 11:05 pm

I had new cylinder liners made at Westwood Cylinder Liners Limited.
This how they went in:

https://www.youtube.com/channel/UCDpmDf ... mo4bm6jE4w

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Simonic
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Re: Z1R Resurrection

#10 PostAuthor: Simonic » Thu Dec 06, 2018 1:28 am

Some great work you are doing here... Looking forward to seeing some more..
'83 ZX1100 '81 Z1000ST, '04 GSX1400, '19 Dodge Challenger Hemi

Philippe
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Re: Z1R Resurrection

#11 PostAuthor: Philippe » Thu Dec 06, 2018 9:02 am

Hi The Living Zed
some very high tech video's and pictures! Thank you for sharing them.
Hope to see more of it.
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!

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Gonzo
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Re: Z1R Resurrection

#12 PostAuthor: Gonzo » Thu Dec 06, 2018 7:59 pm

A very interesting, humerous and informative thread. I'm looking forward to seeing the assembled bike at the end.
1978 Z1000A2
Previous Zeds:
1975 Z1B
1982 Z650F3

deka
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Re: Z1R Resurrection

#13 PostAuthor: deka » Thu Dec 06, 2018 8:01 pm

Second that lookin* forward to the Next instalment
GPZ1100 A1 zrx1100 gsa1200

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The Living Zed
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Location: Cannock, South Staffs

Re: Z1R Resurrection

#14 PostAuthor: The Living Zed » Thu Dec 06, 2018 11:16 pm

I've done the carbs, head and barrels and started buying new stuff.
IMAG0687.jpg

IMAG0681.jpg

Lovely!
I went for 73mm pistons. 1105cc

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The Living Zed
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Location: Cannock, South Staffs

Re: Z1R Resurrection

#15 PostAuthor: The Living Zed » Thu Dec 06, 2018 11:33 pm

Bottom End
I'd forgotten how bad it was.
IMAG0206.jpg

Check the front end out on the right. Hmmmmm Z1R front ends!
IMAG0209.jpg

Notice the improvised tank rubber
IMAG0212.jpg

IMAG0729.jpg

It ain't as bad as it looks - honest


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