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My 1980 Z1R Project 22 Feb 2021 14:54 #843889

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Hey yall,
I finally decided to more fully document my bike project on this forum. I got the bike just before last winter after it sat for 28 years or so. It was my dads old bike and I managed to convince him to let me try and fix it up.(heads up, lots of mistakes have been and will be made) I refreshed the bike last winter, but just enough to get it running to learn how to ride, which I did and I really love it. However, I was frustrated by an ever worsening head gasket leak, and faulty gas tank sealant forced my hand by gumming up the carbs. As such I decided to really tear into it this winter and get it running perfect so I hopefully I can just enjoy riding it this coming season. I have already taken off the carbs, exhaust, camshafts, head, cylinder block and cylinders off. I figured if I was gonna really get into it I might as well replace everything that might need it while I was there. I've got my Clymer manual and I'm confident I'll get her running again. The current state of the bike is attached in the pictures below.
Things I still need to do: Hone cylinders, clean gasket surfaces and combustion chamber, value inspection and adjustment, carb clean and sync, among other things I'm sure that Ill find.
I can certainly post some photos from earlier in the process but it was rather spontaneous and I just tore it down in a weekend or so. Don't worry, I took pictures. I also work at a motorcycle shop which is also a Kawi dealership, so I get all my parts OEM from them.
Besides that I'm going to update this thread as I make progress, which will be sporadic and hectic as I am a full time college student.
Hope you all enjoy the process to come, I'm really grateful for this forum helping me through it all, I've had a hell of a time so far and we're just getting started.
Best, Colin


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My 1980 Z1R Project 22 Feb 2021 23:27 #843906

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Get yourself a factory service manual. You'll be much better off than with that Clymer.

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My 1980 Z1R Project 23 Feb 2021 04:58 #843909

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If you have the cases apart you should change the cam chain. Not much you can do to the crank except listen to the bearings.

Be sure to measure your pistons and cylinders. If you are replacing the pistons in their original cylinders and not changing the rings then no need to hone. Check your valve guides and replace the seals.
I have a couple of Z1B's restored, an '80 KZ1000LTD restored, a 1981 KZ550 restored and a 2008 KLR 650 for off road fun. My wife has a 2019 Suzuki DR 650 for on and off road.

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My 1980 Z1R Project 23 Feb 2021 06:47 #843913

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Definitely will check value guides and replace the seals, and I am planning on putting new rings on the pistons, that's why I am planning on honing. Was not planning on splitting the crankcase however. I'm not sure if that's what you meant or if I can change the cam chain with the bike the way that it is now.


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My 1980 Z1R Project 23 Feb 2021 06:53 #843914

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My 1980 Z1R Project 23 Feb 2021 08:55 #843919

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The cases must be split in order to change the cam chain, or to check the transmission or crankshaft. If you don't plan to do this, you should take your oil pan off and check/clean your oil pump strainer.
I have a couple of Z1B's restored, an '80 KZ1000LTD restored, a 1981 KZ550 restored and a 2008 KLR 650 for off road fun. My wife has a 2019 Suzuki DR 650 for on and off road.
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My 1980 Z1R Project 23 Feb 2021 09:30 #843923

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Ok. I have already purchased a oil pan gasket because it was leaking, so I will clean the oil pump strainer as well while im there.


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