My z1000 lives again...part 2.

So as not to reopen a very old thread I'll link to it and continue here.

My original thread can be found HERE .

Not much has happened with the bike up until about 5 months ago. I ended up putting in storage as I always had a project that take priority over it. Finally after being burned out on wiring up the Gpz, I decided to revisit my first motorcycle.

Note: the tasks below have been done over the last 8-10 months.

I was going to use the stock Zx11 4 pistons calipers but they were hanging up and I bought a set of Gsxr1000 6-pots a while ago for just such an occasion. The caliper mounting bolts were in the right spot but the Zx7/11 calipers use 10mm bolts while the Gsxr uses 8mm. A set of 4 tophat spacers solved that issue as well as correcting caliper offset.



I also need to paint the Zr7 front fender. Nice thing is that it uses the exact same mounting holes as the Zx7 forks.


I found out my leftover Gpz750 speedo cable fits the Zx7 speedo drive and the Kz speedometer. I also grabbed a set of BS34's via eBay and fitted them.

To be continued...

Later, Doug

Fast forward a bit to December. The storage unit where I was storing the Kz and Gsxr experienced a bit of flooding. The bikes were moved to higher ground but it wasn't high enough for the record flooding. After 4 days underwater, the flood receded and I found the bikes knocked over but with minimal amount of damage considering the situation.



During the time in storage I was slowly collecting pieces to update the Kz. I found a Zrx1100 swingarm and an installed but never used Z1 carved seat. I also bought a pair of RFY shocks that were rebuilt by CL MotoTech. I also picked up a set of Carrozzeria wheels but their fate is still undetermined.

After the recovering the Kz from the flood, I was able to get the bike running with a carb clean and a couple oil flushes. With the biggest hurdle conquered, I set about getting the swingarm to fit. I had to shave about 1/4" or so from the pivot and turn up some spacers to adapt the 20mm pivot of the arm to the Kz pivot bolt. Luckily, the arm missed the stock muffler brackets.



I ended up with a spare Brembo rear caliper so might as well put it to use. I pulled out some 5/8" 6061 plate and made a simple mount. I'll get some pics of the finished part later.



To be continued...

Later, Doug

Then I found a Erion Racing muffler for cheap. It was way too long so I cut it down by 6" from 20" to 14".



Took quite a bit to decide on the final angle and position but I think I finalized the location.


I'll try to be a little more diligent in keeping the thread updated.

Later, Doug

looking good Doug keep it up!

^^^^^^^^^^^^^^^^

yessir what Jon said,

keep us posted,

leon

I never liked those mufflers but they're starting to grow on me.
Steve

swest wrote: I never liked those mufflers but they're starting to grow on me.
Steve

I don't mind them but the shock mount on the wider Zrx arm was causing major interference with my V&H megaphone. So instrad of butchering the megaphone, I decided to go with a newer style muffler and fab my own mid-pipe.

Later, Doug

I was able to get out to the garage for a few hours this evening.

Finished up the task of the rear brake mounting setup. Made a brake stay from 3/4" 6061 round stock.


Found out the brake line hoop on the Zrx arm was in the way so removed it




I also thinned mounting point for the brake stay on the caliper bracket by 1/8".



To be continued...

Later, Doug

The rod misses the arm by less than 1/16".



Overall I'm happy with the setup.



Later, Doug

Still need to final weld the mid-pipe as its only tack welded and then make a proper muffler hanger but my exhaust system is at least pieced together. I plan to get the header and midpipe ceramic coated but the budget will determine if that will really happen.



To be continued...

Started working on centering the Zx11 wheel into the Zrx arm. I already had a 5/8" offset front sprocket installed and it's about as offset as you can get before having to do major frame surgery. I was able to line up the chain and sprocket but the wheel was offset to the right about 3/8" or so.


I had a ZRX left side spacer but not the Zx11 and, of course, they're different lengths (17mm vs 12mm). So I took off 7mm (0.276") from the Zrx spacer which pulled the wheel more toward the center of the bike but put the sprocket carrier and sprocket studs very close to the arm.




But that of course moved my sprocket out of alignment.


To be continued...

So I needed to take off material from the carrier but my 7x16" lathe doesn't have enough swing for the carrier to fit so off to the mill and rotary table setup.



I calculated a little over 10mm needed to be taken of the carrier but took off 7mm to match the amount I took off the spacer and leave some extra material, just in case. I mounted up the sprocket the correct way and my chain run was still a bit off so I flipped the sprocket so the dished side faced in and the chain line is quite close.


I ended up getting a laser level so I double checked my rear wheel alignment.



To be continued....