Kawasaki Z650 / 1100

Discussion in 'Some Assembly Required' started by Bevelheadmhr, Nov 3, 2019.

  1. G 981

    G 981 Been here awhile

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    #61
  2. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    With the cylinder block back from the machine shop, the engine assembly could finally continue. Sadly I cant go to my mates workshop (due to our lockdown) where he's doing the build, but he did send me a few pics of progress. Also the head has been rebuilt with new valves, seals and guides..

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    #62
  3. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    It took awhile but finally got hold of a good set of GPz1100B2 cams, which allowed the top end to be finished at last. The stator and rotor and starter clutch were bought new, as used ones are both expensive and rare. A homemade manual cam chain adjuster was also fitted. The outrigger bearing plates wont be fitted until the engine is in the frame, which leaves just the inlet manifolds to be sourced, which in turn will have to wait until I can visit the local Zed shop, to make sure I get the correct parts to fit the Mikuni RS34 carbs.

    The frame and bodywork is almost ready for power coat and paint, the former having been braced and brackets added to support the seat base and battery box. The last job is to fabricate the stainless splash guard and undertray. Again something that will have to wait until the current lockdown ends next month. Getting a smooth finish on the fibreglass seat base has been difficult, in the end we glassed in an alloy plate with turned edges to help get a straight edges to sides of the seat.

    However, I have been recently bought another Zed, this time an unfinished Z1000Mk2 project, which happens to have the engine from my old Z1400 Turbo. The turbo has long gone, but it retains its Orient Express big block. The wheels and rear shocks in the pic below will be replaced with cooler and more expensive aftermarket parts. Oh and I've also been given a Z650 in pieces, which will be rebuilt and given to a friend as a surprise, who is currently bikeless.

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    #63
  4. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    The fibreglass seat base proved to be tricky to get right, in the end we cut away the most uneven section and used an aluminium plate glassed into the underside, to both support the threaded mounting studs and give a smoother, straighter edge to the seat base. Its now gone off to a local upholsterer, who said it'll be done in about 4 weeks. He specialises in camper vans, and he's never been busier than the last year.

    The frame is having a stainless splash guard and undertray made at the moment, and once that's done, just need to tidy up some of the welds, before it can finally go for powder coating.

    I'm going to have to finish my long running Guzzi project, before the final assembly of the Zed can begin, as I have no where else to build it.

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    #64
  5. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Bought a fibreglass replica of a BMW R90S cockpit fairing, seems to fit the front end ok, without the need to modify the fairing. Still got to make its mounts, along with completing the mounts for the 7 inch Z1 headlight. Wasn't sure how it would look on a Zed, but looks ok. My mate said it reminded him of bikes in the first Mad Max film..

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    #65
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  6. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Meanwhile the undertray and splash guard have been made in stainless plate, and the frame has now been powder coated. Just not had chance to go and collect it yet.

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    #66
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  7. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Finally got the Gpz1170 engine in the Z650 frame, though it put up a fight. We had to remove the sump and cut back a tab that had been added to mount the Z1 side panel. The latter being done after the engine had gone off to be rebuilt. There's enough left of the tab that I can drill and mount a replacement for the piece we had to hacksaw off. Thankfully it behind the side panel so will be hidden from view. Note that the front rubber engine mount has been replaced with a solid mount, using top hat spacers.

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    #67
  8. HapHazard

    HapHazard Be Kind - Rewind

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    ^That certainly fills up the space!

    Great progress!
    #68
  9. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    its-magic.gif
    #69
  10. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    R IMG_0154.JPG emoved the hubs from the homemade rear wheel, to clean up the finish, and replace the old cap heads which bolted them to the wheel centre. Hit a problem when the new cap head bolts wouldn't tighten up correctly into the recesses made for them in the base of the hubs. Turns out the old cap head bolts had been machined down slightly so they'd fit the hub. So had to repeat the machining on the new bolts too..
    #70
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  11. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Finally got the engine/frame back home today, so started to test fit parts, to see how it all looks.. when I hit another unexpected problem, this time the lovely upholstered seat - with its fibreglass base which was made on the frame - doesn't fit on the frame anymore, not by a little, but by a lot. Took a few seconds before I realised what had happened.. it'll have to go back to the upholsterer to be completely redone. My fault, as I'd made an assumption, which wasn't the case.

    Can you guess why the seat wouldn't fit the frame??

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    #71
  12. Kai Ju

    Kai Ju Long timer Supporter

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    Cover stretched too tight ?
    #72
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  13. 3legs

    3legs Real men ride sidecars Supporter

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    Check out the great Aussie motorcycle movie " Stone " Just about all the bikes were Z9's. They had the bikini fairings on them. Look great on a Z9.

    They are actually a great little fairing. Have one on my BMW K1100 outfit.

    [​IMG]
    #73
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  14. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    No, its more stupid than that!
    #74
  15. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Great film, saw it on VHS many years ago, I think it came out before Mad Max1 ?
    #75
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  16. villageidiot

    villageidiot Long timer Supporter

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    wrong seat
    #76
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  17. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    No its the right seat
    #77
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  18. villageidiot

    villageidiot Long timer Supporter

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    suspense is killing me!
    #78
  19. Kai Ju

    Kai Ju Long timer Supporter

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    wrong cover
    #79
  20. Tanshanomi

    Tanshanomi Your Favorite Uncle Supporter

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    Upholstery on backwards?
    #80