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KZ900-A5 (Project Bike)
Moderators: chrisu, paul doran, Taffus, KeithZ1R
Re: KZ900-A5 (Project Bike)
I must agree, very nice work!
She's looking good.
GrtZ
Philippe
She's looking good.
GrtZ
Philippe
the differences between a little boy and an adult man is the price and size of their toys!
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
I've recently found that 3D printing has been helpful for making prototype parts and also a few final parts, such as the instrument pods. The following series of pictures show the process I've been through trying to create a new instrument console what will use new electronic clocks, but also trying to keep the spirit of the Z1 incorporated in the finished article. This is a work in progress, pods still need painting and the aluminium clock holder still has its white protective film keeping the brushed aluminium surface scratch free at this stage.
Here is the first mock-up using 3d printed console, version#1
The current status- still needs pods painted and other fittings worked-on, but seems to be coming together.
Here is the first mock-up using 3d printed console, version#1
The current status- still needs pods painted and other fittings worked-on, but seems to be coming together.
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
A few pictures with the latest progress. I have been working on a replacement battery box, oil catch tank and place for M-unit that allows me to use the Z1 side panels rather than the z900. Needed to work on the side panels to open then up to allow the K&N filters to be used. Finally managed to get all the parts to fit.
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
Just a quick update on progress, rear end now nearly complete, just waiting on the ISR rear disc, went this route since it seemed easiest to keep a brake and caliper holder and get the disc made. I've just received the rear wheel spacers and the rear brake toque arm so nearly ready to get the bike on its feet finally.[image][/image]
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
A few pictures to show some progress. I'm hoping that the final assembly of all main items can now commence. Just received the ISR rear disc yesterday so have now fitted the rear end today and hope to have the front end installed during the coming week. The rear shocks used are just a prop until I can work out what will fit.
Re: KZ900-A5 (Project Bike)
Looks great, what gap have you got in that swingarm, I've a davida and on first assessment a 4 1/2" wheel with 160 tyre wont fit
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
Hi Swirl,
I discussed max tyre size with Metmachex before purchasing the swingarm, they said 160.
I have 160 tyre on a 4.25 rim, I've just checked the clearance tyre to swingarm and it is around 17-20mm on each side. Please see photo.
I hope this helps.
I discussed max tyre size with Metmachex before purchasing the swingarm, they said 160.
I have 160 tyre on a 4.25 rim, I've just checked the clearance tyre to swingarm and it is around 17-20mm on each side. Please see photo.
I hope this helps.
Re: KZ900-A5 (Project Bike)
Looking good
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
I managed to get the afternoon in the garage and now have the bike on two wheels. A great relief. I'll be starting on the new wiring this week, not sure how it will go since I have never done a complete loom before.
Some pictures of the procedure....
Some pictures of the procedure....
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
A few pictures that show some further progress:
The wiring job is in full swing, I'm using an M-unit and have completed the low current part for all the switches. Most of the wiring for load items also done, just waiting on some "waterproof" connectors. This afternoon installed the dyna ignition and was able to check and adjust the timing with battery installed. Today I received the hydraulic clutch conversion (slave cylinder) from Falk in Germany.
The wiring job is in full swing, I'm using an M-unit and have completed the low current part for all the switches. Most of the wiring for load items also done, just waiting on some "waterproof" connectors. This afternoon installed the dyna ignition and was able to check and adjust the timing with battery installed. Today I received the hydraulic clutch conversion (slave cylinder) from Falk in Germany.
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
Made some steady progress in the past few weeks, getting close to an engine start.
Tasks completed: wiring finished, HT leads & dyna coils fitted, rear suspension fitted, foot pegs on, hydraulics for brakes and clutch 90%, carbs on, throttle cables fitted, instruments and warning lights done.
Tasks completed: wiring finished, HT leads & dyna coils fitted, rear suspension fitted, foot pegs on, hydraulics for brakes and clutch 90%, carbs on, throttle cables fitted, instruments and warning lights done.
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
Here are the final pictures of the bike with bodywork on, briefly started the bike and seemed to run OK, however the APE cam plugs need to be sealed, oil was coming out!
I have my snagging list to keep me busy before taking it on the road. At the moment I've just attached an old Vance & Hines exhaust, but plan to have a new tail section made in due course when time permits.
Engine running!
I have my snagging list to keep me busy before taking it on the road. At the moment I've just attached an old Vance & Hines exhaust, but plan to have a new tail section made in due course when time permits.
Engine running!
Last edited by kawasaki_man on Sat Apr 11, 2020 10:32 pm, edited 1 time in total.
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- 100Club
- Posts: 156
- Joined: 11th Jan 2012
- Location: Nottingham
Re: KZ900-A5 (Project Bike)
Snagging list fixed and the bike is running well now, no leaks from cam plugs. The bike is taxed and insured and I have completed 68 miles on several short outings. Just knocked out 35 miles this morning before the rain showers come.
Last edited by kawasaki_man on Sat Apr 11, 2020 10:27 pm, edited 1 time in total.
Re: KZ900-A5 (Project Bike)
That looks super smart. Well done.
http://www.airevalleyclassics.co.uk
10% discount code Z1OCTEN
Keyster rebuild kits & carburettor spares - airscrews, jets, needles, starter plungers & gaskets.
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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.