Kawasaki Z650 / 1100

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

  1. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    The rear sets are almost finished, now need to decide on their finish.. probably going to have them hard anodised satin black..


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    While later, a side stand finally arrived in the post.. and I wasn't too surprised when it caused a problem with the gearchange lever.. The side stand will have to be modified.


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  2. Kai Ju

    Kai Ju Long timer Supporter

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    Looks like you might be better off with the linkage rod on top. Can you just flip the shift lever 180 ?
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  3. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Yes could do, though then the ball milling would be on the inside. Can always make another lever if needed.
  4. Kai Ju

    Kai Ju Long timer Supporter

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    Or make the ball milling a slot...if you're worried about strength leave a bridge in the middle.
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  5. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Yes that's an option, the lever would be plenty strong enough with the ball milling slotted. Though the issue isnt so much the linkage, but the side stand hitting the lever. Depends how the lever is angled, too low it'll hit, will have to wait and try it in use to see if it is really a problem.
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  6. baldman1

    baldman1 Long timer

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    I did this same build awhile ago, 1100 engine into KZ650 frame. This is how I did the rearset.
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  7. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Great minds think alike... you've even used the same ZRX12 swing arm..

    After a lot of hassle, the bike is finally on its wheels for the first time..

    The speedo mount is almost done, just need to shape the lower part and paint it satin black. The front end will be getting all new fasteners and brake lines, though still need to buy the clutch and brake master cylinders.

    Waiting for a couple of blank rear sprockets to arrive, which will then need to be drilled to fit the rear wheel hub. The latter being drilled unlike any standard bike.. sigh !

    Hope to try fitting the 4-1 exhaust tomorrow, and no doubt a hundred other jobs that still need to be done. BTW the bars are titled back as the fork preload adjusted get in the way of tilting them up. Shouldn't be a problem when the forks are dropped in the yokes correctly, but we'll see.
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  8. Wildebeest90210

    Wildebeest90210 Long timer Supporter

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    Looking good. I've used R1/6 forks on my last 5 bikes, Hagon recommend and supply YZF1000 thunderace progressive springs which work really well, different pre load spacing, can't remember exactly but if you tell them what your building, weight etc they are really helpful. I found the stock springs were a bit soggy.
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  9. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Good to know, I have found Hagon to be very helpful when I've talked to them in the past. I have also spoken to Maxton, who are only 10 miles away, and they can rework the forks, but at a price.. £400. So want to see how they feel on the road before committing to having them resprung / revalved.

    Here's a pic in daylight.. IMG_0784.JPG
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  10. Wildebeest90210

    Wildebeest90210 Long timer Supporter

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    I've also thought about the Maxton option but I'm not sure I would notice the difference, I tend to ride round suspension issues. The stock forks re-sprung seem to work perfectly well to me and also I can never get past the front desk on the phone to Maxton and never managed to speak to a tech, all done via email. I do use their rear shocks though as I know they are good and like the style. I've used K-techs before which seem just as good to me, they have excellent customer service and even gave me a free re-gas way out of warranty.
  11. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Got the seat back, this time upholstered the correct way around.. Also finished painting the front headlight brackets and polished and fitted the foot controls. Will have the pegs hard anodised at some point, not sure if the levers and hangers will be left polished or anodised black too.

    Next task is to fit the carbs and exhaust, just waiting on a few parts to arrive to do that.

    Then work out how to mount the BMW R90S replica fairing. Once that's done, will have to tackle the wiring, and send the bodywork off for paint. But first need to decide what the paint colour/scheme will be..


    IMG_0875s.jpg
  12. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    With a few more small parts delivered today, I could fit the Mikuni RS34 carbs.. which went on no problem, though I will make a small support bracket to help take their weight, as with no air box, they are only supported by the inlet rubbers.

    Next I fitted the exhaust cylinder head studs, again no problem, followed by the 4 down pipes and 4-1 collector, which also went on the bike with no problems..

    However, once fitted, it was soon clear I had yet another problem, a big problem.. The exhaust was made to fit a GPz1100B1, same as the engine in my bike. But the rear wheel and swing arm are obviously wider than that of an early 80's B1.

    However, I didn't expect the difference to be so apparent, as the collector pipe into the silencer is far too close to the swing arm. There's no way the silencer can be fitted. Also the foot controls are in the way too.. though I want to raise them up anyway, so the kickstand clears the gearchange lever.

    And things were going so well... sigh.


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  13. 3legs

    3legs Real men ride sidecars Supporter

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    Exhaust should be an easy fix. Cut before the bend add a small ring to extend and reweld.

    Looking good.
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  14. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Yep, that's the plan, the only issue is replicating the ceramic black coating on the exhaust once its been cut and welded. There is a local place who specialise in such finishes.. they did the engine cases.. so want to go and see if they can match the exhaust finish before I get the hacksaw out. If not I guess I will just have to spray the welded pipe with HT paint. Luckily it'll be under the engine and not in sight. .
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  15. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    I reluctantly decided that the 4-1 collector of the Delkevic would have to be cut in half and extended by approx 2 inches to allow enough clearance for the silencer. My local welder did the deed, and luckily had an off cut of 2 1/2 inch stainless tubing which was just the right size. I had him fully weld the inner joint but tack weld the outer, that way it will be easy to rejig it if it turns out to be too long or not quite right.

    Once I'm happy with the result. I'll take the 4-1 collector to Cam Coat, who can reapply the ceramic
    finish.

    I may also decide to change the 4-1 outlet, so the silencer is angled up a bit more. Not sure yet. The foot controls are also being raised, by making new hangers.. again.

    In the pic the exhaust is hanging down too low as its not being supported..

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  16. 3legs

    3legs Real men ride sidecars Supporter

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    Looking good. Maybe it's the angle of the photo but I reckon the muffler could be shorter and maybe a little closer to the swingarm.
  17. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Yes it is, though when I hold it up and take its weight, it looks much better. I may cut off approx 50mm from the 4-1 collector exit pipe to move the silencer down/forward a little. Could also mod the collector to angle the silencer higher, not sure. Will wait until the foot controls are re fitted to the bike.
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  18. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Fitted the new, higher unfinished footrest hangers to check clearance with the exhaust, before the 4-1 collector is welded up for good, while its been shortened by 30mm. Everything is ok, except the hangers are now much longer, and much more ugly. They need shaping and made to look as small as possible, before they will be hard anodised black.

    Also with the bike outside now, I could take a few pics of the R90S cockpit fairing held in place, and now I'm having second thoughts. It looks a little too big, and will look even bigger once the large screen is fitted. Might just leave it off for now. The fairing from a Z900rs cafe would work well I think, but OE is far too expensive, and not found any replicas on the aftermarket yet.

    Bodywork is due to go off for paint next month, so need to crack on and make a start on the wiring, and order the master cylinders for the front brake / clutch.

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  19. 3legs

    3legs Real men ride sidecars Supporter

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    For some inspiration check out the bikes from the great Aussie biker movie " Stone".

    Z900's with bikini fairings.

    [​IMG]
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  20. Bevelheadmhr

    Bevelheadmhr Been here awhile

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    Yes that film was one of the inspirations for the look of the bike. By chance was watching it the other night on youtube. I'd forgotten about those 70's custom paint jobs many of the bikes had.. god they were bad!

    That said, if I don't fit the fairing, the single clock looks a bit lost, should've tried to replicate the twin clock look of the Zed.
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