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My Ultimate Zed

Work in Progress

Moderators: KeithZ1R, chrisu, paul doran, Taffus

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Ginger Bear
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Re: My Ultimate Zed

#166 PostAuthor: Ginger Bear » Sun Dec 10, 2017 7:50 pm

Dampers.jpg
I have a couple, one new one used although they're both ** they are very different thicknesses.

PM me your address & I'll get them posted in the next day or so.
Image

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Phil Churchett Award Winner 2011 & 2016 :D
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Re: My Ultimate Zed

#167 PostAuthor: Zomerset Zed » Mon Dec 11, 2017 9:44 am

I have a couple, one new one used although they're both ** they are very different thicknesses.

PM me your address & I'll get them posted in the next day or so.


Thanks for the offer GB! I have ordered the one from Spain that AL put me on to so i will try that one first and hopefully it works. If not i'll get back to you thanks.

Obviously my ebay search skills are wanting :oops:

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Re: My Ultimate Zed

#168 PostAuthor: Zomerset Zed » Mon Dec 11, 2017 6:45 pm

Whilst putting a few miles on the bike i noticed that there was a gap appearing between the end cap and the can of the exhaust. The baffle is a sliding fit in the outer tube with a pressed plate welded to the inlet side and the gas pressure is forcing the baffle and hence cap, so it needs to be held in a bit more securely.

First was to try and locate the baffle by drilling through the outer tube and into the flange of the pressed plate, then cut a thread in the hole in the baffle. This should stop the baffle creeping rearward :shock:

IMG_20171128_152450.jpg


Held in by an M6 button head:

IMG_20171128_153824.jpg


Then measure up for a second screw to hold the cap to the outer tube:

IMG_20171128_155121.jpg
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IMG_20171128_180333.jpg
IMG_20171128_180349.jpg

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Re: My Ultimate Zed

#169 PostAuthor: Zomerset Zed » Tue Dec 12, 2017 10:32 pm

In a previous post i mentioned that the green Dyna coils were a tight fit under the frame rails and i had to find a solution to this. There were other problems too:

One of the HT leads was always trying to work itself out of the coil due to the tight bend it had to make exiting the coil and miss the top frame tube.
I had already blown a fuse once due to the crazy design of the coils placing the LT terminals directly next to the (earthed) mounting post. I had got around this by insulating the terminals and post with insulation tape. i.e. a bodge
When i made the loom i had not fitted the coils, and when the coils were fitted the only place for the loom and its many bullet connectors connecting the main loom with the head loom was squashed in between the top frame rail and in between the coils. This then caused the main loom to be stretched and effectively too short straining all the connectors along its length and causing them to be pulled out when turning the bars :oops Schoolboy error again.

I also suspect that one of the coils is not operating correctly under load and causing the misfire that makes the flat spot in the carburation worse and harder to tune out.

Solution to all this was already sitting in my parts bin for the P&M:

IMG_20171203_133750.jpg


New HT cables too. I like the look of the old style NGK plug caps. How they perform remains to be seen:

IMG_20171203_133758.jpg


The loom is now a better fit around the battery area under the seat but still needs tidying:

IMG_20171203_133816.jpg


I set the ignition system to test mode so that the coils continuously fire. At this point i noted that 2 of the plugs were not sparking across the electrodes but to the side wall - cracked porcelain insulators. So new plugs also went in.

Now starts first press (when the starter clutch allows) and runs much smoother. The huge flat spot just off idle is still there but i am sorting this out soon. There's salt on the roads now so its not going out for a while anyway, so i decided to pull the front end apart awaiting the new bottom yoke from Mikey:

IMG_20171203_131713.jpg


IMG_20171203_132412.jpg

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Re: My Ultimate Zed

#170 PostAuthor: Zomerset Zed » Wed Dec 20, 2017 7:32 pm

Picked up some anodised parts from Mikey:

IMG_20171216_151148.jpg


Bottom yoke, headlight brackets and rear brake torque arm:

IMG_20171216_151201.jpg


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Gotta say he does a perfect job. This is one service supplier i am very happy with :D

Spent an hour or so pressing the stem out of the R6 yoke and into the new one with the bearing and spacer:

IMG_20171219_142233.jpg


Needed to turn down the stem slightly for thicker than anticipated anodising, but she went in with a bit of juggling :tooled

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Re: My Ultimate Zed

#171 PostAuthor: bunnysZ » Wed Dec 20, 2017 8:27 pm

very nice where did you get the head light brackets from , do they fit a 43mm fork
zed the best ride of your life ...... so far

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Re: My Ultimate Zed

#172 PostAuthor: Zomerset Zed » Thu Dec 21, 2017 10:08 am

very nice where did you get the head light brackets from , do they fit a 43mm fork


I designed them and had a local CNC company make them, then got them black anodised.

They are for 53mm USD forks but could be designed/made to fit any size.

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Snag list

#173 PostAuthor: Zomerset Zed » Sat Jan 13, 2018 6:41 pm

Got me fork extensions back from the machinist:

IMG_20171223_131313.jpg


Internal extension fitted with copper washer to stop any bypass:


IMG_20171223_140233.jpg


Top extender fitted with new o-ring:

IMG_20171223_140542.jpg


Screwed in as tight as i could get it, but its not going anywhere once all clamped:

IMG_20171223_140640.jpg


This now gives me 30mm more fork length to play with.

All finished with new seals and 26ml additional fluid to each fork.

IMG_20171223_152223.jpg

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Re: My Ultimate Zed

#174 PostAuthor: chrisw1 » Sat Jan 13, 2018 7:02 pm

loving this thread ......some very nice mods and engineering but keeping the soul of a z

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Paintwork

#175 PostAuthor: Zomerset Zed » Mon Jan 29, 2018 6:25 pm

Tank, side panels, tail-piece and front muddy are all at Dream Machine for the exotic paint treatment. I asked John to replicate the following as close as he can except for Silver rather than gold on the tank and tail-piece:

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Kawasaki Z1 RCM-257 by Sanctuary Tokyo West 08.jpg (76.54 KiB) Viewed 1240 times
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Kawasaki Z1 RCM-257 by Sanctuary Tokyo West 03.jpg (84.27 KiB) Viewed 1240 times
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Kawasaki Z1 RCM-257 by Sanctuary Tokyo West 01.jpg (82.62 KiB) Viewed 1240 times
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Kawasaki Z1 RCM-257 by Sanctuary Tokyo West 05.jpg (85.83 KiB) Viewed 1240 times


Blue is to be a cobalt Kandy similar to my old ZXR:

DSC00922.JPG

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Carbs off again

#176 PostAuthor: Zomerset Zed » Thu Feb 01, 2018 10:25 pm

Time to get the carbs off for the following:

Pilot jets up from 17.5 to 20
Main jets down from 130 to 120
Install air corrector jets

Mr Pigford had sent me a set of 0.6mm air corrector jets that i was going to fit to my carbs. Unfortunately Postman Pat decided to keep them for himself :evil:

To remedy the situation i got my hands on some 5mm natural couloured nylon round bar and turned it down in the drill with some emery paper to just under 5mm to slide into the airway that feeds the emulsion tube. I also ordered some 0.6mm drill bits to make them:

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Fiddly and small springs to mind:

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Had to hold the nylon in the drill chuck and offer up the drill bit in a small pair of mole grips to drill the hole, then cut off with a saw and sand to finish. Used super glue to hold them in place.

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Re: My Ultimate Zed

#177 PostAuthor: Pigford » Fri Feb 02, 2018 8:45 am

Excellent work - well hacked off those correctors got lost !!!
And on the 7th day... Zeds were created!

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Re: My Ultimate Zed

#178 PostAuthor: Zomerset Zed » Fri Feb 02, 2018 11:27 am

Excellent work - well hacked off those correctors got lost !!!


Me too matey. Only thing i have seen lost in the post for ever and so precious too. Checked with neighbors but i am on the lookout for a local postman with a 70's/80's jap bike running pods :P

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Sprocket cover

#179 PostAuthor: Zomerset Zed » Fri Feb 23, 2018 7:07 pm

Decided to make a cover over the sprocket to stop splashing up the hole, so to speak :P

IMG_20180210_153445.jpg


Made up from a piece of 2mm ally plate and backed with 1mm rubber sheet

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Fits between the outrigger plate posts neatly and is in there pretty tight once the plate bolts are done up

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Glued, and done :P

IMG_20180217_124039.jpg
IMG_20180217_124046.jpg

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Re: My Ultimate Zed

#180 PostAuthor: Zomerset Zed » Sun Apr 15, 2018 6:23 pm

I finally got the finished paintwork back from Dream Machine. Can't fault any of their work and they did exactly what i asked for-this may be a 1st for me :shock:

Got it all mounted and badged up and did some other minor mods like liberating the fuel tap of the diaphragm, so now its just for decoration.

After much procrastination i find myself the owner of some new Mikuni RS flatslides. With yesterdays weather it was too much not to fit them and take it for a test spin:

It goes well :P

Then needed a bit of a wash (its muddy here in Somerset)

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Now needs some miles, some air filters, fiddling and MOT


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