[CaTacL1sm]

Here's the caliper on the disc/hub, need to make a new carrier for it (not sure what model the existing one is for).

I think if I make a spacer for between the disc and the hub, I should be able to clear the spokes

 

[CaTacL1sm]

Ok so I ordered the following:

-Z1 1/2" rear master cylinder kit from PMC
-96 link DID o ring chain (up 4 links from the stock 92 to give myself breathing room for the swingarm. I can always remove a link or two)
-Z1 630 front 15t sprocket
-KZ1000 630 rear 35t sprocket


The only thing I need to order now is spokes.

I'm fairly certain that since my D.I.D rear rim is 3", that I have a deep drop center rim. I need to double check the inner diameter of the rim to make sure it's 16.375" or so. Did a quick attempt with a tape measure, but with the wheel installed it's obviously hard to get an accurate measurement.

 

[jcw]

Sorry to go off topic here...

I was researching some wheels and did a search for webike and your thread pops up a lot. I was wondering if you have ordered from them and how your experience was.
Their price on japanese made wheels, Galespeed, are $500+ cheaper even when you figure in shipping.

 

[CaTacL1sm]

I've ordered from them twice so far, used PayPal both times. The first time I used them (for the z1 wiring harness) one of the items was backordered. They sent an email in English explaining such and I responded with a request to cancel that item. They promptly did so with no issues.

I just ordered again from them with no issues so far.

One thing to keep in mind is that the post office will probably require a signature for whatever you order. If you pick it up at the post office, be sure to let them know it's an international shipment and not domestic... I found out my post keeps them separate after some confusion

 

[CaTacL1sm]

So my NOS Giuliari seat arrived from France today...

I know I just bought a reproduction one from Germany a few weeks ago, but when this one popped up I had to buy it.

All it really needs is a little bit of re-gluing if the cover back to the seat pan.

The neat thing about it is that the hump is fiberglass whereas the reproduction one is has a hump made from padding.

I think I may get some new sidecovers and leave the 900 badges off.... I think it looks kind of silly having it on both the seat AND the sidecovers

 

[seanbarney41]

love those seats...your bike just keeps getting better and better

 

[knappyfeet]

I agree with seanbarney41. .........it just keeps getting better.

I see my GS in the last pic....how's that doing?

 

[CaTacL1sm]

Thanks all, gotta keep improving the foxhole!

The GS is probably better than ever after upgrading the electronics with a motogadget... all I need to do now is track down the slow leaks in the tires and possibly replace the fork seals (I have a sneaking suspicion I installed them upside down).

And i think that's my CB77 project you see

 

[CaTacL1sm]

So I went a little manic...

I started off by test fitting the fancy alloy inner fender/tool box I scored on ebay for cheap (it's made by PMC, the same boutique company that made the wiring harness).

That led to me going back in the house and ordering an alloy rear fender eliminator (the previous owner made a real hoodrat fender eliminator)

Then I went back out into the garage and figured, since I was going to be putting the airbox back in, I might as well take the time to re-paint the battery box and adjust the wiring...

Here you can see the poor mans fender eliminator/license plate bracket, as well as the well patina-d battery box. The box doesn't have any serious rust, but could use a fresh coat of paint.

I also took some time to adjust the wiring... The upgraded harness and fuse system has a really nice stainless mounting bracket. The catch is that the edges on that plate are somewhat sharp. Generally, as long as you're good about routing you shouldn't have anything to worry about. I wanted to do further rerouting as well as cover the edges to protect the wiring.

I actually switched around the order of those plugs to make more sense given where their respective wires come from and go to. I also covered the edges of the opening in wiring a few layers harness tape. I may go back and use some sort of rubber edge molding, but I think that may reduce the clearance by too much.

Here's a better view of my protective measures.
With the fuse panel on, you can't tell anything has been done.

I also need to dig out the original fender so I can pull off the Z1 tail light. The lucas is cool and all, but I think I'd rather go with one that suits the bike a bit better.

 

[CaTacL1sm]

Some more progress...

Had a few packages arrive today including stuff from japan, as well as a rear fender bracket from johnnys motorcycles.

The airbox adapters are incredible. They're perfectly machined for a snug fit, and have a 1/1.5mm set screw to keep them on. I need to go get some smaller allen wrenches to be sure.

There's also no interference with the lower air jet (despite what it may look like):

I will need to trim the stock airbox manifold to get everything to fit. I'm going to measure a set distance (in this case from the intake manifold to the sidecover mount). Then I'll measure the distance from the intake manifold to the carb mouth. After removing the carbs and installing the airbox, I'll measure the distance from the sidecover mount to the end of the airbox manifold. Some simple math later and I'll know how much I need to trim from the airbox.

BUT I won't be able to do that until the paint on the battery box dries.

This box is in fairly good condition, but I'm tempted to get the stainless steel one from PMC in japan... it's stupid expensive, but the quality is amazing. Maybe next year.



I did get the alloy inner fender and tool box "installed". I just need to get new mounting bolts for it. I'm a little concerned that it doesn't go as far down as the stock one, but I can always add a small mudflap to the bottom. The other concern is that this fender is flat vs the curved stock one. I doubt the tire will impact it (given that this is a pretty popular upgrade on Z1/Z2 bikes in japan), but I'll keep my eye on it.

I also went into storage and pulled the original tail light off of the stock fender. It cleaned up nicely, and I think it will look better than the lucas tail.

Lastly I went and put all my receipts and documents pertaining to the Z1 into a binder. There's still a ton of receipts I need to print from email as well.

I have a problem.

 

[CaTacL1sm]

did some measuring:

As you can see, I'd need to cut WAY too much off the airbox to get these to fit (carbs currently extend out to 5-7/8" and the airbox goes to 4")
Its and easy fix though, I'm just going to need to order shorter carb-motor adapter spigots. I think I had originally gotten the long ones because the shorter ones weren't in stock... annoying.

 

[Cyorg]

Interesting frame for you. An endurance racer from back in the day.

 

[CaTacL1sm]

That's really neat. Who made it?

 

[CaTacL1sm]

Installed the original tail light and the knockoff aluminum fender eliminator. There's a guy on eBay who makes copies of the Japanese ones for 1/2 the price.
The only issue is that I need to re-drill two of the mounting holes.
Also... the license plate bracket must be spaced for Japanese plates :/

Here's where I need to put the new bolt holes:

 

[CaTacL1sm]

So I got everything back together last night, to include the new shorter carb spigots and cleaning up the tail light and rear blinker harnesses.

Today I took advantage of the 60 degree weather to ride over to the machine shop to drop the bike off so we can finally begin the rear disc upgrade

I also got a new battery with the right terminal orientation so my cables laid correctly. Annoyingly, the new stainless tool tray doesn't quite fit my leather tool case+tools:

I also added the Z1 rear tail, which I like a lot better than the lucas tail:

I still have more cleaning to do, it's amazing how much road grime gets kicked up:

And finally the short carb-head spigots. They keep the carb outlets flush up against the intake boot.

I'm also going to have Tannermatic make me a belly pan... just because.

 

[CaTacL1sm]

So I did a baking-soda "sandblast" job on the rear hub.

Before:

After:

That was after about 5 minutes or so of blasting.
The good thing about baking soda is that it's gentle and it washes away with water.

All I have to do now is rinse the hub off and put the new bearings in.

 

[CaTacL1sm]

We have liftoff

 

[TrialsRider]

Holy, there is something you don't see on this site every day,
a motorcycle with fenders. The man's a rebel.

 

[CaTacL1sm]

Started pulling stuff off during my lunch break today.

The chain was definitely due for replacement.

And I have a lot of cleaning to do while everything is apart, not to mention touch up paint.

I also pulled the gauges to send out to be restored. I found the mounting bracket was cracked as well so I ordered a new one (plus harness and dampers) from Z1E. I figure if I'm paying to have the gauges restored, I should fix the rest of the assembly too.

 

[CaTacL1sm]

So I'm second guessing myself on whether or not the 18x3.00 rim on the drum hub will fit the disc hub. I sent an email to Buchanan to see what they think. (I am aware of how much I don't know when it comes to building wheels... thankfully my machinist is willing to take the time to mentor me).