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Hey Gordone.,thanks very much. I appreciate the kind words.
At the moment its too hot to do anything here in Holland.Today I spent a lot of time in the basement. Its very cool down there. Im repairing/renovating
 my 'bakfiets' (cargo bike).When the heatwave breaks,Ill get back to the Z.

I just spent the last few hours reading this entire thread and find that is one very interesting build (not my style but I love the workmanship that has gone into it) and I hope you get everything sorted soon, keep us up to speed on it.

Thanks for that Bruce,a lot of work to read through the whole thread. Be careful though,reading through other peoples build threads is what finally prompted me to start my own!! You have been warned.

Spring seems to have sprung here in the lowlands. A cracking day today. I didnt put the bike in storage this winter,its just been sitting outside on the street, under an overhang on the building next door,so, out of the rain but exposed to everything else. Today was cleaning day ( #1) . A good scrub behind the ears. The worst affected was the exhaust. a second hand 1980s job that I got off ebay. The chrome was already a bit pitted and worn in places and the top of the down pipes where they fit into the head, have no chrome. The rust was really starting to blossom, so that got a good polish. It came up ok. Tomorrow,I want to pull the downpipes off and give them a good going over. I cant get at everything when its on the bike. The paint seems to be holding up really well ( My first attempt at painting) and a bit of Turtle wax brought that up lovely. Very happy with it. The powder coating on the wheels and swingarm looks good with no chips or bubbles.The engine is a real mess though. The engine cases are oxidizing and the PJ1 is knackered.Apart from the mess where fuel took it off, theres a small oil weep from the head ( I think) and thats taken more paint off. The rest has oxidation showing through. Itll be a repaint this summer im afraid.
Other than that,its not looking bad at all (especially for a bike thats sat outside all winter). A bit more cleaning tomorrow and that should be it sorted. Oh and it started up no problem.

such a cool bike!
nice work still looking great.

leon

Thanks Leon. Where have you been? Yup,getting it ready for the season again. Its all cleaned up and de-rusted. Very happy (and surprised) that it started up so easily the other day. I ordered some packing for the exhaust today and Ive been looking at the handlebars. The ones I have fitted are not so comfortable. Too wide I think. Also,I noticed that the left hand side is flexing, which cant be good. I have a couple of other sets downstairs,Ill try them out over the weekend. There are a few other small jobs I want to do this year but mainly I want to get out and do some riding.

still around,haven't posted much.
we are having a cold,wet, nasty winter here in oklahoma(no snow just the rest of the sh!t) and i don't have the central heat and air installed in my shop yet so we have been hibernating.
my Z1R has fresh rubber a charged battery and is ready to go,as soon as we get some decent weather:silly:

leon

Sorry to hear that Leon, were having great weather here these last couple of weeks. Having my lunch breaks outside in just a t-shirt last week!!. Today,working on the bike again (outside). I got the exhaust baffle packed. See here;
www.kzrider.com/forum/2-engine/610099-exhaustion

I also changed the bendy handlebars. I had a shorter steel chromed bar. About 70cm,compared to the 80cm bendy set. A bit of a tight squeeze getting everything fitted and re routing the cables to avoid having to shorten anything but what a difference it has made. The bike feels totally different. It feels quicker, more nimble, more responsive. I had a quick blast around the block and it felt like a different bike!

I haven't been on in while but man it was a great pleasure to see this bike finished. What a great looking beastie you have created. Nice work David.

Thanks Larriken, I also havent been on for a while and Ive hardly touched the bike all summer. My mind has been in other places and I bought an old XT 600e, with the aim of doing a bit of TETing next year. Ive been a bit occupied with getting that sorted;


We did have some nice weather here at the weekend so I rolled the Z out back of the house and gave it a good clean. I also made a list of all the odds and sods still to be done to finish it properly;
A proper battery strap ( Ive been using an old bicycle inner tube!)
2/ 45 degree plug caps ( I have 90 degrees on the outer cylinders and they stick out funny)
Engine paint. (the PJ1 didnt work out and lets the whole bike down)
Bars ( I changed the extra wide set as they were too flexible The only other set I had were too straight and hit the fork tops)
The Velcro holding the seat down is not working as it should,I have to sort that.
A set of decent nuts for the down pipes
and I need a cover for the clutch adjuster ( the bike came with a crappy homemade job)

So thats whats left to do. I did get another set of bars with a slight raise and a slight pull back. They seem to sit better on the risers and just about clear the fork tops. Theres also more room to tie the switch cabling up properly now. Of course,being a useless twat,I snapped the clutch lever mount as I was refitting it!!! So thats another thing for the list( I ordered a new one today). On top of that,as I drove off to collect the new bars, I forgot the back wheel was still chained up! So a big clunk and a sudden stop but thankfully the only damage I could see was the number plate neatly folded in half.
Thats it for now,Ill post any updates as they happen. Though it might take a while.

Time to sort out the clutch cable. I bought an original CSR cable which was way to long for the bike as it is now, so Ive been using a 2nd hand cable of unknown origin. Thought Id have another go at shortening the CSR cable.
So I measured up the original nipple,length/diameter ( I think 10mmx 6mm) I took 2 sraps of alu plate and drilled a 6mm hole all the way through the first and about 4mm into the 2nd. Bolted together,I was able to drill a 2mm hole perpendicular for the cable to rest in. Things were a bit tight so I drilled it out again to 2,5mm (which turned out to be a bit too big)

Some flux, a good bit of heat and some plumbers solder, an it came out like this

I was a bit too brutal seperating the plates

2nd attempt was better and then I went for the real thing. Go tstupid first though

The real thing

It came out pretty good,I think

and cleaned up well

A new cable perch to replace the old one that I snapped

and now I just have to road test it