1400 Mk2 Restomod

[Bevelhead]

Drilled the new Renthal bars to take the wiring from the M-Switches, fitted the bars to the bike, along with the HEL master cylinders and grips. Next task is to make a bracket to mount the speedo/tacho unit, and once that's done, I can finally make a start on building the wiring harness for the bike, despite not having an engine yet....

[Bevelhead]

The headlamp mount 'ears' have been machined to make them less ugly, while a steel bracket has been made to fit the speedo/tacho gauge. These have been painted black, and now just need to complete the alloy part of the mount and that the front end fabrication done.

[Bevelhead]

Having an interesting time trying to build the wiring harness for the MK2 without an engine. Can't do everything, but I can do approx 90%. The keyless ignition system is on back order, but the GPS speedo sensor should be here in a few days.

Using an M-Unit simplifies things a lot.. no need for a fuse box, alarm system, relays, etc. Though the wires from the M-switches are tiny, and tricky to work with.




Have to work on my drive now, between the rain showers, as no room left in my garage

[Tony]

Just being nosy what’s the frame off next to the mk2 cheers tony

[Bevelhead]

Z1000A1, start of a future project..

[Bevelhead]

Collected the XJR1300 swing arm for the Z1000A1, which has been powder coated. The faces which hold the wheel adjusters were left uncoated. as the powder coat would soon get scratched when the wheel was moved to adjust the chain.

While made a start on making the bracket to hold the speedo/tacho unit to the Z900RS top yoke.

[Davehales]

Z1000A1, start of a future project..

This looks like what I was thinking of doing, z900rs wheels?

[Bevelhead]

Yes Z900RS wheels and forks. I found the rear wheel and new forks easily on Ebay, but finding a matching front wheel is proving difficult. I keep looking. I also bought a Z900RS swing arm and caliper too, but the arm cant be modified to fit the frame. A pity, so went for a Yamaha ZJR1300 arm instead which was easy to narrow to fit the frame.

[Bevelhead]

Completed the speedo/tacho mount, then fitted R&G bar ends to the Renthal bars, after buying different bar ends which didn't fit, as the Renthal bars have thicker walls than a standard steel bar. Next a pair of HEL brake lines where fitted, two lines rather than the OE three, so called race format.

Dropped the idea of using a GPS speed senser, was it wasn't so easy to fit with the Daytona speedo.. but will use the GPS option on another project. However, the magnetic senser wouldn't fit between the fork leg and front disc, as there isn't enough room. So had to make a mount to fit it next to the rear disc.

The senser was intended to be mounted to the fork leg with Zip ties. Had to file a grove in the new mount to stop it from swivelling on its one 3mm mounting screw. Once painted black should be pretty much invisible.



















Also finished making the stainless engine mounting bolts, 10mm stainless rod cut and threaded, and once the hex nuts were welded into place, they were skimmed on a lathe.

[Bevelhead]

Can't do much more with the MK2 without its engine, but recently collected the ported head and its now gone off for ahigh tech coating. Once that's done it can go on top of the engine, and the engine can go in the frame at last.

In the meantime, been working on the Z1000A1. After 8 months of looking finally found a good front wheel, from a Z900RS, so once I fit a new tyre n the week, I can assemble the rolling chassis very loosely. See how it looks for the first time.



Made a mount for the KOSO speedo/tacho, from a piece of 4mm plate, bent 45 degrees. Once shaped, it'll need to be finished in satin black to match the yokes. Also needed to make a housing for the GPS aerial needed for the speedo, made from a piece of 20mm alloy. It has a perspex window, not in the photos. May still do a bit more work on this, may look ok, once painted.





Also bought a carbon fibre front mudguard from a German supplier, called FF carbon. Need to make a suitable mount for it, as don't like the factory mount, looks too angular.

[Bevelhead]

Spend the morning loosely assembling the Z1000A1.

With no rear shocks yet, the bike almost fell over when I tried to fit the second fork leg, as the additional weight unbalanced the frame. Therefore, I had a look in my garage for something to link the swing arm to the frame. I found an old alloy tool I made years ago for another task, quickly drilled it and it worked ok in place of the shocks.

Once the front end was fitted it was no longer needed. Though I had to refit it when taking everything apart later.

Found a few unexpected problems along the way, good to find out now rather than later during the final build.





Z1000A1 seems smaller and more compact than the MK2 though it probably isn't really

[Davehales]

Looking good, i may go for z650RS wheels?

[Tony]

It’s like a Kawasaki production line

[Bevelhead]

It’s like a Kawasaki production line

Only if Kawasaki made one bike every year or two..

[Tony]

Like they say it’s quality not quantity that counts