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Z1000-A1 Restomod

Work in Progress

Moderators: chrisu, paul doran, Taffus, KeithZ1R

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TiBolts
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Re: Z1000-A1 Restomod

#16 PostAuthor: TiBolts » Mon Jun 22, 2020 3:50 pm

Instalment 5
Sorry, it's been a while - the next bit involves wheels and although I got rebuilt ones back in Jan or Feb, I thought I'd taken photos of them but couldn't find the pics so I must have deleted them accidentally. So I needed to unbox the wheels (they're well packaged!) to take new photos of them - which I've just done.
So... back to the project. I had a Z1000-A1 rear hub that came off the write-off that I had back in '87 that I built into a Magnum II. It had been a mate's bike so I thought I'd like to use this hub, even though I don't strictly need an original rear hub. The bike came with cast wheels and I wanted wire wheels and also slightly wider rims than standard. So I needed a front hub, and got one via eBay from some guy in California, and it was very reasonable money. Then later on I found the original front hub that I've had for over 30 years in the attic... never mind!
Anyway, the hubs were blasted and powder coated down at RPA in Bristol along with the frame etc, then I fitted new bearings. The original rear one had the inner spacer missing so a mate made me one out of ally, and I had an ally one made for the front hub too. Then I looked at what size wheels to go for. My Hinckley Bonneville has a 19" front and a 17" rear and I could see that there's a lot more choice of rear tyres in 17" compared to 18 so I mocked up the chassis with the original rear wheel and then the Bonnie one to see what it was like - bearing in mind that the rear end is jacked up slightly because of the different (Bandit) swingarm. I don't want it jacked right up like I see some, even if I'm tall enough to still ride those. Photos:
028_Whichsizewheel01p.jpg
029_Whichsizewheel02p.jpg
030_Rear_hub_brg01p.jpg
031_Front_hub_brg01p.jpg

Of course, the engine isn't fitted which is going to compress the front end somewhat, but it gives me a good idea. I decided to go 17 inch - so a 2.5 front rim (19") and a 4.25 rear. Sent off the hubs to Central Wheel and not long after some expensively rebuilt wheels turned up.
034_wheels_arrive01p.jpg
They package them well, don't they!
035_wheels_built01p.jpg

During this time, the chroming was also ready for collection so I had some nice shiny parts. However I still needed a front mudguard so treated myself to a nice new genuine Kawasaki one from Zed Power.
Next up - I take the engine to bits!
Cheers
033_New_fr_mudguard01p.jpg
032_Chromed_parts01p.jpg
Attachments
036_wheels_built02p.jpg
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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chrisNI
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Re: Z1000-A1 Restomod

#17 PostAuthor: chrisNI » Mon Jun 22, 2020 5:23 pm

Luvley shiny bits... :)

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Re: Z1000-A1 Restomod

#18 PostAuthor: r3sc » Mon Jun 22, 2020 5:37 pm

I’m liking that, the re chromed items look great and when it’s done the bike will look the same.

Keep the posts coming!

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TiBolts
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Re: Z1000-A1 Restomod

#19 PostAuthor: TiBolts » Mon Jun 22, 2020 7:10 pm

Yep next instalment coming soon!
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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Re: Z1000-A1 Restomod

#20 PostAuthor: TiBolts » Tue Jun 23, 2020 5:37 pm

Instalment 6 - the engine!
Well. When I bought this collection of parts I tried as best I could to examine the engine and I couldn't see any damage except for scrapes and so on - the generator cover had a crack in it too - and I was particularly careful to check the exhaust studs. They had all been removed and all the threads are good, so that was OK. Once I'd got the bike home I sat the engine in the corner of the garage on a pallet and basically ignored it for ages. Then when it was time to start on it I took the cam cover off and checked the clearances - all OK, a couple a tiny bit tight, but fine, and I drizzled some oil over the cams because I wanted to do a compression test. The starter motor had already been removed and as I was putting it back on I noticed that one of the lugs for the two M6 bolts that secure it was broken off... bugger. And worse, one of the M6 crankcase bolts in that area was also broken off, and difficult to get at to drill. Well if I'd known I would still have bought the bike but maybe I could have haggled the price down a bit... lesson learned, check more carefully before buying!
Anyway, I did the compression test and it spun over pretty well, but the compressions varied from 125 to 147 psi. So what with that and the damage to the engine - I thought I'd strip the whole thing down and give it a good once-over. This turned out to be a good idea, since on removing the sump I found the remains of the small front cam chain guide lying there looking all beat up... and lots of the rubbery/plasticky stuff from it all over the oil pump screen. Which I had a photo of, taken with my nice macro lens in super close up but that seems to have disappeared too. Well you can see it from the photo of the engine just after I'd removed the sump.

Here are several photos of the first stages of the engine strip. I suppose a lot of people on here have done this many times but hopefully enough of you will find it interesting. I like seeing what other people are up to bikewise! As you can see, I started with the motor on wooden blocks (they are an awkward shape, aren't they!) but I'd ordered the type of engine stand that used to be available through the club, now via eBay so that arrived and is just the job.
037_engine_strip01p.jpg
Luckily the impact gun was enough to get the clutch nut off without a holding tool

038_engine_strip02p.jpg
The other side...
039_Sump_off01p.jpg
Mucky sump and oil pump screen
On removing the cams I also removed the revcounter drive and the lug that attaches the holding plate for that was broken off too :x
040_Cams_out01p.jpg
Cams about to come out...
041_Head_nuts01p.jpg
The cylinder head nuts were really on tight!
042_Head_off01p.jpg
But with a bit of persuasion the head came off
043_On_the_bench01p.jpg
Now on its stand on the bench... bloody barrels are stuck fast though
044_Barrels_moving01p.jpg
After a week or so, got the barrels moving. A bit gritty round the studs
045_Barrels_moving02p.jpg
Another view of the barrels putting up a fight
046_Gud_pins_out01p.jpg
Pushing the gudgeon pins out with a bit of old bamboo. Yes I did support the piston with my other hand! Luckily they weren't too tight
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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Re: Z1000-A1 Restomod

#21 PostAuthor: TiBolts » Wed Jul 15, 2020 11:23 am

Instalment 7 - Engine stripped
Once I'd got the barrels off the rest of the motor came apart easily enough, except for a few broken crankcase bolts :lar - but I knew I already had two to deal with anyway. The strange thing was, one of them snapped without even much pressure being applied and I'm not strong in the arm...
The other main issue was that the gasket was well and truly stuck to the bottom of the barrels - more on that later. There was quite a lot of grit and stuff around the studs to clean up. They look quite manky in the photo but cleaned up reasonably well. Not sure whether to replace them...
047_upside_down01p.jpg
Motor upside down and on the stand
048_crankcases_split01p.jpg
Crankcases split
049_brokenbolts01p.jpg
Waaa! More broken bolts
050_crankcases_empty01p.jpg
Cases now empty
051_crankhousing01p.jpg
Arty shot
052_selectorcover01p.jpg
Gaskets came off the side covers easily enough
053_topcrankcaseempty01p.jpg
Yeuch! Could be worse though

Next up: removing gaskets, taking the valves out, measuring ring gaps etc, stripping and rebuilding oil pump, carbs... the list goes on :)
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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chrisNI
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Re: Z1000-A1 Restomod

#22 PostAuthor: chrisNI » Wed Jul 15, 2020 1:09 pm

You definitely did the right thing pulling it down... :shock: :D

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TiBolts
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Re: Z1000-A1 Restomod

#23 PostAuthor: TiBolts » Wed Jul 15, 2020 5:03 pm

chrisNI wrote:You definitely did the right thing pulling it down... :shock: :D

Yes, for sure... the barrels are being rebored at the moment and I've got all new camchain and tensioner parts to go in, plus whatever else it needs really. The crankcases have been repaired and just waiting for them to be vapour blasted so hopefully start rebuilding the motor soon.
:D
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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Re: Z1000-A1 Restomod

#24 PostAuthor: TiBolts » Fri Sep 25, 2020 12:21 pm

Sorry it's been a while... work has been continuing though bit by bit...
Gaskets removed, crankcases repaired, carbs rebuilt, oil pump rebuilt, barrels rebored, head, barrels and crankcases and a few other bits vapour blasted, various bits purchased (new crankcase bolts, output shaft bearing, odds and sods). Now getting ready to rebuild the motor. But here are some photos of a few of the jobs done earlier this summer...
... photos seem to have disappeared, so have uploaded them again. More to come soon...
Attachments
065Carbsdone1.jpg
063_carbmountvapblastd01p.jpg
062_carbnewbits01p.jpg
060_carbcleanup01p.jpg
059_ultrasonic1p.jpg
058_carbbitssorted01p.jpg
056_removevalves01p.jpg
055_base_gasket02p.jpg
054_base_gasket01p.jpg
Last edited by TiBolts on Tue Feb 16, 2021 10:06 am, edited 1 time in total.
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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Re: Z1000-A1 Restomod

#25 PostAuthor: relisysxx » Fri Sep 25, 2020 6:20 pm

Been looking for a set of Zed Thou alloys if you feel like paring with them?

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Re: Z1000-A1 Restomod

#26 PostAuthor: TiBolts » Mon Sep 28, 2020 3:26 pm

relisysxx wrote:Been looking for a set of Zed Thou alloys if you feel like paring with them?

Oh! Sorry, already swapped them with a mate for some other parts.
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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Re: Z1000-A1 Restomod

#27 PostAuthor: relisysxx » Mon Sep 28, 2020 6:19 pm

No problem, I'll keep looking :)
Keep up the good work!

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Re: Z1000-A1 Restomod

#28 PostAuthor: TiBolts » Fri Feb 19, 2021 1:17 pm

More progress has been made... moving almost as quickly as a glacier.
Photos hopefully self explanatory, more to come as I'm ahead of these photos even :o
Attachments
074_bottomendrebuild3p.jpg
073_bottomendrebuild2p.jpg
072_tabwashers1p.jpg
071_bottomendrebuild1p.jpg
070_oilpumpdone1p.jpg
069_oilpumpclean1p.jpg
068_oilpumpsplit1p.jpg
067headvapblastd1p.jpg
066casesvapblastd1p.jpg
:mrgreen: 2006 Bonneville T100 (lightly customised) and Z1000-A1 (nearly finished!!!)

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Re: Z1000-A1 Restomod

#29 PostAuthor: Ultim8pc » Fri Feb 19, 2021 1:59 pm

Coming along nicely..
http://www.airevalleyclassics.co.uk
10% discount code Z1OCTEN
Keyster rebuild kits & carburettor spares - airscrews, jets, needles, starter plungers & gaskets.
Also petrol/ethanol proof float bowl gaskets. IMD pistons preferred seller.

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Re: Z1000-A1 Restomod

#30 PostAuthor: JimBoUK » Fri Feb 19, 2021 8:40 pm

Looking really good.
It’s exciting getting to the stage where the finished bits start going back together


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