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TOPIC: Z1b winter upgrades... when you fall down the rabbit hole

Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:09 #799209

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So coming into fall of 2018 I had the Z1 in a pretty good spot. I had upgraded the brakes, electrical, and forks over the summer and managed to get the bike on the dyno to finish tuning the CR29s.
I'm and idiot though and can't be happy with things the way they are.
Here's what the bike looked like before we began ruining things.



The plan for the winter then, was to upgrade the rear wheel from drum to disc. I picked up a 76 KZ750b (same as a KZ1000) rear hub, a grimeca caliper, and a PMC rear master cylinder kit to use as the basis for the swap. I would need to machine some spacers for the rear wheel so I rode the bike over to my friends machine shop and we got it up on the lift.



For the purists out there, everything I change on the Z1 is reversible and I often buy second parts so I don't have to disassemble or modify the original. (though this leads to an ever growing pile of original stock parts that I need to find a place to store).

Since this forum doesn't like too many links per post, I have to break this up into a few sections.

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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:10 #799210

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First I'll go into detail of the rear wheel.
I picked up the hub a few months ago on ebay. It was in pretty good shape, but could use a cleaning.



I hit it with my home soda blast setup and it cleaned up nicely:





Since the spoke angles on the Z1 and KZ rear rims are different, I'd have to go with a new rim in addition to spokes. So after installing new wheel bearings, I sent the hub off to buchanans to be laced up (time is more valuable to me than money right now).

I went from a 3.00 x 13" DID to a narrower EXCEL 2.50 x 18" rim.
The results were spectacular.







So I couldn't just have an Excel rear rim and a vintage Akront front rim...

I ordered an H2/Z1 front hub (at least I'm pretty sure its an H2 hub due to it being black) and had that laced up to an Excel rim as well. I'll get pictures of that once I pull the current front wheel off and swap over the discs.

As for tires, I'm running Avon Roadriders.

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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:10 #799211

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The Master cylinder assembly I ordered off of japan.webike is great. The bracket bolts right up to the Z1 frame and it should work perfectly with conventional peg/brake lever. Well I'm running tarozzi rear sets so it wasnt quite right:



It was a simple fix however, just a matter of cutting off the tab of the tarozzi "actuator" and welding on a new one:







And a coat of paint:



And complete:

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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:11 #799212

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After that it was a matter of bolting it up and finding a spot for the reservoir.

All bolted up:



and the rear master cylinder reservoir mounted to the oiler reservoir bolt holes.



I should add that I'd also gone full aluminum inner fender, tool box, and fender eliminator by this point (as well as refinishing the battery box):





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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:11 #799213

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My machinist had a few big print shop jobs at this point so I had to occupy myself with other things until he could do up the spacers.
Thats when I decided to restore the gauges.

The previous owner must have gotten in a minor fender bender at one point:









So I sent the gauges off to Z resto and bought some new parts to compliment them:



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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:12 #799214

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The gauges came back from Z resto and were beautiful.



I also cut down a section of old handlebar to use as a filler for the empty stock handlebar mounts:



I used the end plugs as well to give a more finished look:





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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:12 #799215

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I also went and did a few more minor things, like refinishing the (tired) engine cases in a brushed aluminum finish:



and replacing the missing high beam switch (although I may look at eventually replacing the entire rocker switch internal, since the plastic tab is partially broken):



I just glued it on:



Then the bellypan from Tannermatic arrived:



I'll have to wait until I get the rear disc complete before installing that.

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Last edit: by Move0ver.

Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:14 #799217

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While I loved the UNI filters, I had to trim away a lot of the side cover to get everything to fit.
I ordered some new K&N filters to allow me to use sidecovers that had only been minorly trimmed (the fuel line still needs to be trimmed and clamped by the way):





And I installed a 2" competition baffle (it was a tight fit, I need to touch up the paint a bit now):

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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:14 #799218

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Most currently, I have some new decals...









Silver and white instead of gold and white. I'm holding off on the upper two white stripes until I can find a good dark grey vinyl to cut and use instead of the normal black. (the color of the bike is Audi Moro Blue).

And I put the first coat of paint on the sidecovers:



The following user(s) said Thank You: KZJOE900, Scirocco

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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:15 #799219

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So thats where we stand as of today. The things I still need to do are as follows:

-Axle spacers
-Instal chain
-Make rear brake line
-Rebuild Grimeca caliper
-Adjust locking post on Giuliari seat
-Swap front discs over to new wheel and balance
-Replace stator grommet
-Instal Randaks grips

I think thats it?

Like I said, everything I've done to the bike is reversible and the bike is completely restore-able to stock.

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Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:38 #799221

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I like it!
Nice upgrades.
Fairing is staying silver, matching the side covers?
Rob.
CANADA
http://www.kz650.info/

'78 KZ650 C2, 125K kms, Rickman fairing, Delkevic ex, EI, K&N, ATK fork brace, steering damper, braced swingarm, Progessive & Koni, 18" Z1R front wheel.

'00 ZRX1100, Ohlin's shocks, fork brace, steering damper, ELS +4, Corbin seat, Gimbel bugspoiler.

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Last edit: by rstnick.

Z1b winter upgrades... when you fall down the rabbit hole 25 Feb 2019 16:42 #799224

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yep

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Z1b winter upgrades... when you fall down the rabbit hole 26 Feb 2019 09:26 #799254

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Love the work you been doing! Everything done with quality. Wheels look great! Post a picture of her once you are done with the upgrades of her in the sunshine with some nice background to to it justice.
Current project 76 KZ900 (This was a Vetter model)
76 KZ900
81 XJ550H SECA (Current Project)
82 XJ550R SECA
Past:
86 FJ1200
74 Z1900
72 CB450

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Z1b winter upgrades... when you fall down the rabbit hole 26 Feb 2019 12:29 #799261

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Move0ver, just a suggestion.
The Tarozzi rear brake mechanism get a lot of play over the time into the joints.
I made a bracket for the rear MC and a banjo bolt brake switch. Works great for me with no Play.






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Z1b winter upgrades... when you fall down the rabbit hole 26 Feb 2019 12:53 #799263

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When you say joint play, do you mean left/right movement in the barrel actuator linkage?

My MC is mounted pretty much the same way as yours only on the inside of the frame

I appreciate the advice, I just want to make sure I understand exactly what you're saying.

Edit:
I'll add, I've modified the drum brake version of the tarrozzi rear sets to work, meaning I'm still utilizing the stock brake pivot to actuate the piston.

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Last edit: by Move0ver.

Z1b winter upgrades... when you fall down the rabbit hole 26 Feb 2019 13:24 #799270

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I am talking about the extra linkage mechanism.


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Z1b winter upgrades... when you fall down the rabbit hole 26 Feb 2019 13:33 #799271

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You can adjust the leveler with this pin to the right angle you need.

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Z1b winter upgrades... when you fall down the rabbit hole 26 Feb 2019 14:14 #799274

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Got it.

I see what you're getting at, with reducing the number of pivot points (you're using a direct link from the pedal to the MC rod, I'm using like... 3 pivot points).
I see a few improvements I can make in tolerances, but I'll try using this current setup first. The alternate is to just create a completely new arm that directly link the pedal to the rod, much like your setup (albeit with a big angle in it).

The pin between the new arm and the master cylinder is a very tight tolerance, but the two pins in the linkage between the foot peg and the barrel have significantly less. I could look at machining up two new pins and a new H-linkage to remove any slop in the system. The barrel fits over the frame mount very snugly, and when properly lubricated operates smoothly.

While I had no complaints of sloppiness when using these with the drum brake, I can imagine there will be some things more apparent with the new setup.

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Last edit: by Move0ver.

Z1b winter upgrades... when you fall down the rabbit hole 26 Feb 2019 15:35 #799283

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Give it a try and expand your MC to the outside of the frame with some longer bolts and washers, just like proof of concept.



It´s an easy try and error, i have go the same way as you first and ended up with my Setup.
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Z1b winter upgrades... when you fall down the rabbit hole 27 Feb 2019 08:06 #799330

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Changed the oil and replaced the leaky stator cover grommet:



Got the supplies from johnnys vintage. He loves Spectro oil, so I figured I'd give it a try.



I wasn't sure if I still had the oil filter washer so I ordered a spare... sure enough, I'd lost it at some past oil change.



Whoever removed the cover last sure loved red RTV...





It's a good thing I'm replacing the whole sub-harness...

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