'78 Z1-R Restoration Progress

Saweet!
That's my all-time favorite kawi kolor!
Nice job.

weales wrote: Yep, I think that only the US/Canadian models had the short rear guard -
the one on my bike came from a repro mob in the UK (LPM).
The European version was also released with the long guard.
I must admit I like the shorter guard but this wasn't available at the time
and I'm trying to keep the bike as close as practcable to its original appearance.
Mind you, it'll have a non-std exhaust which departs somewhat from the original.
(BTW the Delkevic 4:1 exhaust arrived yesterday, looks great and I can't wait to get it fitted! )
Ordered this from the QLD distributor last Friday - pretty good postal service!
Cost me $569-95 (including GST and postage).

Is that $569.95 in USD? Wow big price difference from the same one I bought. www.delkevic.us/index.php?route=product/...Z1000D%20(1979-1980) .................................................Mike

Vroom-vroom!

The $569-00 was $AUD and equates to about $399 USD at the current exchange rate.

very nice progress pics!


leon

Have had problems with the starter motor clutch making awful "can of nuts and bolts" noises and slipping when engaging starter.
Pulled the alternator rotor/starter clutch off and found that the three bolts securing the clutch to the alternator rotor were tight but that the clutch was still not locked to the alternator rotor. On closer inspection I found that the holes in the rotor which had been drilled and tapped to accept the three cap head bolts had a lot of burring which prevented the bolts from being fully tightened. On removal of the bolts it was obvious that this was the case as they had been rattling around and were all buggered! (see pic)



So I've got new High tensile steel bolts and have cleaned up the threads in the alternator rotor with a tap. The dowel pin is also buggered and I'm waiting for a new one - should be here next week. I showed the clutch starter gear to a mechanic and he agrees that the boss through which the clutch drives is worn undersize and is the reason for the slippage (just like Ed said!) I have tried to get a repair to the boss done - thought I could get the boss built up (hard-chromed) then ground/machined back to size but nogo! The lip of the ring gear prevents anything but a really small grinding wheel (ie less than about 50mm diameter) from getting onto the boss - bugger! So I have ordered a new gear from Partzilla - will cost me about AUD $365-00 with shipping and exchange rates! Anyway you gotta do what you gotta do!
Will keep you posted!

dammit! :pinch:
sorry to hear of your misfortune.

brightside is when it is together and "right" you'll appreciate every start just a lil bit more.

leon

G'day leon,

Thanks for the encouragement - sometimes that's all we need to get us over the hill!

Be interested to hear if anyone else has had to deal with this problem and what they did to solve it.
The boss diameter was only .020" undersize (compared to unworn portion) and thought that this wouldn't have been enough for the slutch rollers to slip on? Ed posted a pic of a new Vs a worn starter gear boss so maybe it's a combination of the undersize and the shiny surface - believe that originally the boss had some fine annular grooves that the rollers could "bite" into?

see pic

I wonder if those fine grooves allowed oil to be squeegeed off the boss so the rollers could bite?

That could be it, Ed - anyone else got anything to offer?

Every used starter clutch I've ever seen looked like Ed's "used" photo. I don't think such a surface finish denotes "bad" unless the ridges are too deep.

I have three or four of them. They all look like that. I changed mine not because it was slipping, it was loose on the crank more than the one I replaced it with. They're pretty tough on the big fours.
Steve