Dutch 1977 Z1000 Build

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10 Feb 2017 07:29 - 10 Feb 2017 10:11 #754041 by Wiers
Replied by Wiers on topic Dutch 1977 Z1000 Build
750 R1,
I just cut off what I was thinking what looks good, almost broke my friends saw due to the glass fiber inside clogging up.
For mounting you can just use the clamp and the ring/gasket type of thing.
If you tighten the clamp the ring will expand and seal of the exhaust.
This only works if you have a snug fit with both pipes, mine did not.
I had to enlarge the muffler intake and coupling to the size of my pipe (63mm).
Then I welded a ring i made about 2 inch down the pipe which holds everything together.


Here you can see the ring still at the end but I moved it about 3cm inward.
(don't forget to place the ring with the 3 holes before you weld something like I did :S )

I found a picture with how it is now, top right corner.



It may be Chinese crap but it looks and sounds great :laugh:
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Last edit: 10 Feb 2017 10:11 by Wiers.

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10 Feb 2017 07:49 - 10 Feb 2017 07:52 #754044 by Wiers
Replied by Wiers on topic Dutch 1977 Z1000 Build
First ride in 12 years for me and 3 years for this bike!



First I made a temporary bracket for the exhaust.


The fact that it is freezing and started to snow lightly did not stop me from my first ride in a long time.
The bike handles well (okay I did not past 45mph :lol: ).
The brakes are working and I did not have any problems (yet) with ground clearance.
Even on the speed bumps.
This saves me a lot of work on fork extension.
So on the positive:
Handling
Brakes
Electrical
Clutch
Sound :laugh:

On the negative:
Could not rev up full.(looks like it is starving and the fuel filters are not filling up fast enough)
When I stop nr3 carb is pissing fuel trough its overflow hose (float bowl??)
Some rattling form parts which I have to tighten or modify.
And strange leaking from the Body breather ( the Chinese hose has to be replaced) but it looks like a sort of foam.



But the bad part is still the oil leak from the head gasket.
Went by the Kawa dealer and if I have it fixed by him it cost me a lot of money.
He charges $200 for the gasket and O ring alone :sick:

So it is doing it myself and take a change of messing it up or find a fellow biker who can do it for me.

Eric
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Last edit: 10 Feb 2017 07:52 by Wiers.

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10 Feb 2017 09:14 #754052 by davido
Replied by davido on topic Dutch 1977 Z1000 Build
Hats off to you Eric,going out in this weather. I had to go out west of town (1/2 hour) to pick up my fork extensions.Not fun.
First thing I have to say is to stay away from official Kawasaki dealers .They are going to be the most expensive place to have work done.Find an independent workshop,itll be a lot cheaper.Also,buy the gasket yourself.
As for the filter,I was looking at a small one that I could hide under the tank but my local shop told me they are for scooters and dont allow enough fuel to pass through..I have one now about 5cm long and 3-4 cm wide.Of course I havent fitted in yet,What are you using?
How is your VHT paint coping with the leaking carb?

P.s. For the head gasket, with a workshop manual you should be able to manage it yourself.Youve gotten this far.

www.kzrider.com/forum/11-projects/594313-csr1000-project-build
CB550 (1978)
CB500/4 (1972)*
KZ1000CSR (1981)
XT 600E (1999)
TDM900 (2003)

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10 Feb 2017 10:09 #754053 by Wiers
Replied by Wiers on topic Dutch 1977 Z1000 Build
Hi David,
I was thinking the same about the dealer.
I guess I will be starting the job myself and "see where the ship strands" (dutch expression :) .
And when I get stuck I can always bring the pile of parts to someone else.

First I started out with larger fuel filters but with the same result now I have the same size as which where one the bike when I bought the bike, maybe there is some blockage in the petcock but when I open it while not connected fuel flows out quick.
For now I know the bike starts and runs, until the weather is nice outside I will be doing small cosmetic stuff inside.
Eric

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10 Feb 2017 11:07 - 10 Feb 2017 11:08 #754055 by 531blackbanshee
Replied by 531blackbanshee on topic Dutch 1977 Z1000 Build
congrats on the first ride going as well as it did. :evil:

as for the headgasket replacement.
as davido stated buying the gasket yourself and doing the work is going to be the cheapest solution.and well within your ability and plus you'll get to learn more about your street weapon :evil:
which is always cool. :)

leon

skiatook,oklahoma 1980 z1r,1978 kz 1000 z1r x 3,
1976 kz 900 x 3
i make what i can,and save the rest!

billybiltit.blogspot.com/

www.kzrider.com/forum/5-chassis/325862-triple-tree-custom-work

kzrider.com/forum/5-chassis/294594-frame-bracing?limitstart=0
Last edit: 10 Feb 2017 11:08 by 531blackbanshee.

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10 Feb 2017 14:07 #754065 by 750 R1
Replied by 750 R1 on topic Dutch 1977 Z1000 Build

Wiers wrote: 750 R1,
I just cut off what I was thinking what looks good, almost broke my friends saw due to the glass fiber inside clogging up.
For mounting you can just use the clamp and the ring/gasket type of thing.
If you tighten the clamp the ring will expand and seal of the exhaust.
This only works if you have a snug fit with both pipes, mine did not.
I had to enlarge the muffler intake and coupling to the size of my pipe (63mm).
Then I welded a ring i made about 2 inch down the pipe which holds everything together.
Here you can see the ring still at the end but I moved it about 3cm inward.
(don't forget to place the ring with the 3 holes before you weld something like I did :S )

I found a picture with how it is now, top right corner.



It may be Chinese crap but it looks and sounds great :laugh:


I didn't mean it was Crap, just that it was cheap, I think its very good quality, just like you though, I think its a bit long. Thanks for the pics, My solution was a bit more complicated, I think you may have just saved me some time... :cheer: , thanks....

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  • SWest
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  • 10 22 2014
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10 Feb 2017 18:16 #754075 by SWest
Replied by SWest on topic Dutch 1977 Z1000 Build
Your fuel starvation could be the tank vent. I have two small inline filters with 33mm carbs. Plenty of flow.
Steve

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11 Feb 2017 03:12 #754089 by Wiers
Replied by Wiers on topic Dutch 1977 Z1000 Build
Thanks guys for the encouragement, just the little push I need.
I am gonna do it myself :)

750R1,
You are right about the Chinese quality, expect what you pay for.
Until now it always exceeded my expectations and are happy with the shipping times.
Only one thing I ordered never arrived but that was sadly due to a cargo plane crash in Kyrgyzstan last month.
And I never know if I buy something from a "dealer" if it is the same stuff made in the same factory but then 10 times more expensive.
But to be sure the parts which are live savers like brakes etc. I buy in Europe or the US.

Steve,
I think you are right, it must be something else.
The filters I have now are the same size as which came of and the other ones I tried where larger and gave the same problem.
So it is either the petcock ore the fuel vent.
But what about the fuel dumping trough the overflow hose? Can that be a float valve or something like that?
Eric

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12 Feb 2017 08:03 #754153 by spdygon
Replied by spdygon on topic Dutch 1977 Z1000 Build
Congrats on your bike....looking good. As far as the head leak pretty straight forward.
Manual best friend....

1982 GS1000sz Katana ( #15...17K Miles)
1982 GS1000sz Katana ( # 297....7100k Miles)
1978 Kz1000 Z1R. 10K Miles1
1978 kz1000 z1r 27k miles
1977 KZ 1000 A ( Project ) 54K Miles
1976 Kz900A4 (Red)21K miles
1976 Kz900A4 ( Red)7500 miles
1974 Z1 900 project

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19 Feb 2017 06:04 #754553 by Wiers
Replied by Wiers on topic Dutch 1977 Z1000 Build
Took the carbs of and found that in nr3 one of the floaty things was bend upwards.
Bend it back equal with the other one and no more overflow:)
Did a few more test rides but same problem with "fuel starvation"?
Looked at my fuel filters and this is how it looks.


Not much fuel in there, also slow flow(more dripping)
If I take the tank of and open the petcock fuel streams out fast enough.

Before next ride I will put back old main jets(the plastic ones) and see with that does.
Also exhaust is very open, no DB killer and not welded on the joints.
So I will put in a DB killer to try and compensate for all the leaks in the exhaust department.
Now it is waiting for the weather to clear up and do some cosmetic stuff.

Eric
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  • SWest
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  • 10 22 2014
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19 Feb 2017 07:55 #754560 by SWest

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19 Feb 2017 09:19 #754568 by davido
Replied by davido on topic Dutch 1977 Z1000 Build
What Steve says.Plus check the fuel tap and make sure thats ok. Also,try a bigger fuel filter and see how that goes,the one in the photo looks quite small( and Is it the right way around?).Another thing to think about,how dirty is the filter? If its clean (and you have been running the bike) then do you really need it??

www.kzrider.com/forum/11-projects/594313-csr1000-project-build
CB550 (1978)
CB500/4 (1972)*
KZ1000CSR (1981)
XT 600E (1999)
TDM900 (2003)
The following user(s) said Thank You: SWest

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