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TOPIC: New rebuild after 10 years "deep sleep" mode

New rebuild after 10 years "deep sleep" mode 17 Feb 2017 15:50 #754416

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For the old glory see my posting in the new member section

Sadly awaking after 10 years of no movement :( :( :( :( :(
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New rebuild after 10 jears "deep sleep" mode 17 Feb 2017 16:07 #754417

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First act !!!
Slaughterhouse time for the donor bike,( need somebody else parts form the bike ).
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New rebuild after 10 jears "deep sleep" mode 18 Feb 2017 04:04 #754460

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Here some pictures from the ZX9R fork installation from last year.

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New rebuild after 10 jears "deep sleep" mode 18 Feb 2017 04:23 #754461

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Front brake lines install and comparing 18 x 3.50 Akront with 17" ZX9R wheel.
Sorry for the blurry handy pics
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New rebuild after 10 jears "deep sleep" mode 18 Feb 2017 14:39 #754513

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Hello again, here are some pictures from my January progress.
ZX9R rear wheel and chain / rear sprocket adjustments.

Facts:
Z1B swing arm inner width 250 mm
ZX9R swing arm inner width 265 mm

Z1B axle diameter 20 mm
ZX9B axle diameter 25 mm

+ 15 mm for wheel, disc brake parts and rear sprocket holder to fit in my swing arm.
+ 5 mm for the bearings and Z1B swing arm axle.

Impossible but not really.

My solution:

I cut the ZX9R axle to 249 mm length and bore it out to 20,15 mm inner diameter.
So i can slide through my special axle for the eccentric chain adjustment. +5 mm problem solved.
The rear sprocket holder inner bore for the bearing was drilled 4 mm deeper on the lathe.
The supporting surface for the rear sprocket was machined off 10 mm and the front surface was shorted
( i don't know exactly but i think is was 12 mm ).
Shorten the spacer sleeve for the sealing and bearing support to 12 mm length. +15 mm problem solved.

I hope it is understandable for everybody, if not i will make same exactly measurements and pictures.
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New rebuild after 10 years "deep sleep" mode 18 Feb 2017 15:16 #754514

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Lift the bike and set it exactly straight with a spirit leveler at the upper frame tubes.
Mount a cross laser spirit lever on a camera tripod.
Adjust and check front and rear sprockets with an long steel ruler for off sets.
Wheel looks centered for me. Any different opinions or suggestions ?
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New rebuild after 10 years "deep sleep" mode 19 Feb 2017 04:22 #754548

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Hello again

Here some pictures from my last 2 weeks progress.
Tarozzi footrest system and rear master cylinder mounting bracket.
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New rebuild after 10 years "deep sleep" mode 19 Feb 2017 04:26 #754549

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I also modify the rear caliper bracket for a better support to the swingarm mounting plate.
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New rebuild after 10 years "deep sleep" mode 21 Feb 2017 14:53 #754786

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Hello Scirocco, Nice bike mate. I prefer the spocked 18 inch wheels, period wheels look better on these old bikes IMO. I have some old wide DID rims in storage that will get a run on one of my old Honda 4's...
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New rebuild after 10 years "deep sleep" mode 21 Feb 2017 15:17 #754788

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Hello 750 R1
Yes you are right 18 inch look better but here in Germany the tires for 18 inch wheels are
very expensive, up to over 230 Euros and more for the rear tire, because they are not so popular anymore.
17 inch rear tires cost 100-140 Euros.
Later in my project i will return back to my old Akront 5.75 x 18 ( with disk hub ) and 3.50 x 18 wire wheels.
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New rebuild after 10 years "deep sleep" mode 21 Feb 2017 15:22 #754789

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BTW, a current status of my bike and a little tech upgrade.
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New rebuild after 10 years "deep sleep" mode 22 Feb 2017 01:38 #754807

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Hi Scirocco,
Nice project, the donor bike looked like a very new bike.
It looks almost done.
What are your plans for further modifications?

Eric
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New rebuild after 10 years "deep sleep" mode 22 Feb 2017 08:40 #754828

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Hello Wiers and thank you.

The donor bike was a good deal,PO needs money quickly.
Unnecessary parts go for cheap,bike technically accepted by official test institution (TÜV) for one and a half year.

My next plans for the future are new modern speedometer and rev counter in classic style.
Hydraulic clutch,big bore 1100 ccm maybe more, shim under bucket, GPZ 1100 UT cams, Mikuni RS 34 or injected (these parts I have).
(my Z 1000 J head is ported and has new valves, guides, valve seats !!! shim thickness 2,95 - 3.20 mm !!!)
But before i go deeper into my project first cleaning all dusty,dirty and rusty parts of the bike. refurbish electrical wiring harness and the most important things for the official test institution (TÜV) and firt street legal riding in march.
You see a lot of work to do.

Later going back to my old Akront 5.75 x 18 ( with disk hub ) and 3.50 x 18 ( new modified hub ) wire wheels.

PS: I am searching for a tail light like yours (Honda RC ???)

Michael
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New rebuild after 10 years "deep sleep" mode 22 Feb 2017 09:47 #754834

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nice work !

leon
skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
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New rebuild after 10 years "deep sleep" mode 22 Feb 2017 14:14 #754858

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A little update from my todays progress.

Rear brake pedal



Lithium Ion battery installed

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New rebuild after 10 years "deep sleep" mode 22 Feb 2017 14:16 #754859

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carbsync checked ( # 4 a little out of sync )

MVI_1565_2...22-2.avi

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New rebuild after 10 years "deep sleep" mode 22 Feb 2017 14:19 #754860

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Fuel filters looking good ( tank was sealed with POR15 20 years ago !!! ).



Stainless cap nut for rear suspension reworked form
Metric 10 x 1,5 to M 12 x 1.25 for rear shock absorber mounting



Even more stainless nuts, bolts, washers for later works.

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New rebuild after 10 years "deep sleep" mode 08 Mar 2017 14:02 #756181

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Hello kz riders

Nearly two weeks without updating my project but i was not inactive.
I can do only little steps now, a lot to do at work,plus repairs and maintenance
for my friends and colleagues bikes, (bike season starts end of march).
Remove rear wheel and swing arm for cleaning and bearing replacement.

Here is my rear wheel axle and sprocket hub setup
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New rebuild after 10 years "deep sleep" mode 08 Mar 2017 14:15 #756182

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Front and rear wheel bearings.



Swing arm out for cleaning and polish



More will come after the weekend

By the way, i need some recommendations or opinions for digital classic speedometer, tachometer or 2 in 1.

Michael
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New rebuild after 10 years "deep sleep" mode 08 Mar 2017 15:17 #756188

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some more cleanings on engine case and front sprocket
Lock washer pin has to be file smaller but the price of 20 cent is it worth.



Michael
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