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1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

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Philippe
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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#31 PostAuthor: Philippe » Sat Dec 22, 2018 5:24 am

Hi James
good for you that the air filter box is supple. I hope it'll fit.
I noticed that the previuos owner fitted an oil cooler. If you leave it off, find a new housing for the oil pressure warning switch and use 4 pan head screws to mount it.
I changed the intake rubbers on my '72 Z1. It's easy; cut off the vacuum intakes, tap thread in them, put a screw in and make sure they're air tight. Oh and use pan head screws to attach them to the cylinderhead instead of the allen bolts.
Take care with the camchain tensioner! Don't use too much pressure on the lock bolt, the housing cracks very fast!

@ baz: from approx engine number Z1E-2200 the vacuum intake was changed from the head to the rubbers.
GrtZ
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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#32 PostAuthor: pignog » Sat Dec 22, 2018 10:45 am

James, photo of labels under seat, there is a helmet hook either side with a label.
I have used all the original fastenings, just cleaned them with solvol and wire wool.
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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#33 PostAuthor: JamesH_Sussex » Sat Dec 22, 2018 12:17 pm

pignog wrote:James, photo of labels under seat, there is a helmet hook either side with a label.
I have used all the original fastenings, just cleaned them with solvol and wire wool.

That’s really useful - really appreciate you taking the time to post this..

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#34 PostAuthor: JamesH_Sussex » Fri Jan 25, 2019 11:45 pm

So after a bit of a Christmas break and not being able to do any painting because of the ambient conditions, have managed to make some more progress with the Z.

Original shocks fitted, rear grabrail fitted, a bit more work on the electrics completed and have managed to progress the paint on the engine.

The objective isn’t for a concours finish here - the bike has patina everywhere so I’m just looking for a decent original looking finish to the engine. Have cut back the fins on the LHS of the engine to see what finish I can expect and so far so good. Hoping to progress more over the coming days.

A few more photos:

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#35 PostAuthor: wilsonsjw11 » Sat Jan 26, 2019 9:10 am

James,
Good to see the original HT cable clips on top of the cam cover have survived the years.
Regards
Steve

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#36 PostAuthor: z2.john » Sat Jan 26, 2019 10:32 am

FYI, these are the decal locations.
The Brake fluid decal was either positioned at the factory where it is shown but could also be put on top of the LH side cover.
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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#37 PostAuthor: JamesH_Sussex » Sun Jan 27, 2019 3:24 pm

Thanks John, decals ordered..

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#38 PostAuthor: JamesH_Sussex » Mon Jan 28, 2019 3:21 pm

So, engine paint is finished, all polished cases put back on with fresh gaskets and correct JIS screws, ribless carbs put back on with fresh fuel lines, oil back in. Not long now until first fire for 20+ years. Bores oiled many weeks ago and has been turned over by hand with plugs out for the past few weeks quite regularly.

Realised I’m misssing one carb—>airbox clamp and the clutch cable is the wrong one. Also original speedo cable is shagged, so two new cables ordered from z-power.

Biggest issue at the moment is the starter solenoid appears to be knackered. Starter button is fine but I’m measuring open circuit on the input to the solenoid. So may need to find a replacement working solenoid.

Few pics from today...(bright sunlight not ideal)

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#39 PostAuthor: marmck » Mon Jan 28, 2019 3:48 pm

Looking Good :clap :clap :clap

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#40 PostAuthor: Philippe » Mon Jan 28, 2019 5:19 pm

Hi james
she's coming together, she's beautiful ! Nice restoration.
I've enlarged the pictures of the clocks. They're original, the speedometer has the 20 offset and the rev counter has the straight 7. Seems to be the original '72 clocks.
I'm afraid that the needle of the rev counter will wobble... look at the distinctive circle around the needle axle, it seems to me that the rev counter has been kept upside down and that the damping fluid leaked out...I hope I'm wrong.
If you should consider to open the clocks, you can clean the gauges with alcohol and give them back the black colour by rubbing them with wet cigar ashes... just keep in mind that I don't want you to start drinking and smoking in order to restore your Z1...these are just a few tricks I use to restore the gauges.
Anyway, she's at the right place.
GrtZ
Philippe
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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#41 PostAuthor: JamesH_Sussex » Tue Jan 29, 2019 4:33 pm

Philippe wrote:Hi james
she's coming together, she's beautiful ! Nice restoration.
I've enlarged the pictures of the clocks. They're original, the speedometer has the 20 offset and the rev counter has the straight 7. Seems to be the original '72 clocks.
I'm afraid that the needle of the rev counter will wobble... look at the distinctive circle around the needle axle, it seems to me that the rev counter has been kept upside down and that the damping fluid leaked out...I hope I'm wrong.
If you should consider to open the clocks, you can clean the gauges with alcohol and give them back the black colour by rubbing them with wet cigar ashes... just keep in mind that I don't want you to start drinking and smoking in order to restore your Z1...these are just a few tricks I use to restore the gauges.
Anyway, she's at the right place.
GrtZ
Philippe

Many thanks Phillipe. Will let you know how the gauge performs after the first start. It's bloody cold here so I think the issues will only be apparent when it warms up a bit. I may send the gauges off for some professional attention; we'll see.

have found & fitted a replacement starter solenoid - just a few electrical gremlins to sort now & she'll be ready to fire up hopefully.

More soon..

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#42 PostAuthor: Andrew_s » Tue Jan 29, 2019 5:57 pm

Hi James,

Saw this thread on the SOHC, not sure how I've missed it?! :shock:

The Z1 is coming on very nicely and I'm a particular fan of originality (not to the point of counting rivets though!) and I really commend you for the approach you're taking with it - looking forward to seeing the finished article.

Cheers
Andrew
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Phil Churchett's 1976 Z900 A4: PRE 2R https://www.flickr.com/photos/115740825@N05/albums/72157680116996884
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2023 R1250 GSA
Previous Zeds: Z750B1 Twin, Z650B1, Z750E

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#43 PostAuthor: JamesH_Sussex » Tue Jan 29, 2019 11:28 pm

Thanks Andrew, appreciate the feedback. It’s a very tough line to tread - working out how far to go with refinishing parts whilst trying to retain the originality. Hopefully I’m doing the bike justice. We shall see..

Andrew_s wrote:Hi James,

Saw this thread on the SOHC, not sure how I've missed it?! :shock:

The Z1 is coming on very nicely and I'm a particular fan of originality (not to the point of counting rivets though!) and I really commend you for the approach you're taking with it - looking forward to seeing the finished article.

Cheers
Andrew

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#44 PostAuthor: JamesH_Sussex » Tue Jan 29, 2019 11:43 pm

Bit more progress this evening - but a bit of ‘two steps forward, three steps back’. Have been trying to trace some electrical issues. PO appears to have removed and refitted the pilot light loom, and helpfully fitted all of the lights in the wrong location. So the oil light was illuminating the high beam, neural light the oil light etc...

Also, have an issue with the LH switch wiring - there is a blue male connector that connects to the double blue female connector from the RH switch. When connected this blows the main 20A main fuse when I toggle to the High beam position. Doesn’t happen when the male blue is removed from the RH double connector. So i need to re-check the wiring. Have removed the headlight so incan properly probe the wiring loom before refitting.

Couldn’t resist test fitting the original black foam seat. It’s in really lovely condition (aside from a tiny 2/3mm tear on the LHS and some wear on the lower LH edge. I’m missing the seat prop hardware so will need to source that.

Starter solenoid issue resolved and the engine cranks over nicely on the electric start and builds nice oil pressure.

Should be able to fire her at the weekend all being well.

Also fitted the new safety/caution stickers that arrived in the post today.

Few more photos:

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Re: 1972 Z1 Recommission / Rebuild - Vin # Z1F-01173

#45 PostAuthor: Philippe » Wed Jan 30, 2019 5:16 am

Hi James
electricity troubles...hard to find the reason on a 40+ years old bike. Make sure that the main loom and the switches are both US or EU. If mixed up that could explain the trouble. I hope you have the wiring diagrams from both the versions, if not, find them on the web and check everything out. Don't forget to install the resistance between the blue wires from the left and right hand switch to prevent the bulb from blowing each time you rev up.
Don't forget: electricity, it's a kind of magic. You'll have to become an apprentice! :idea:
Good luck
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!


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