Author Topic: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.  (Read 13145 times)

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Offline 754

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #225 on: February 06, 2020, 06:21:35 pm »
Bill how long does it take to set the points ?
 Is there more room under the Webers ?
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Offline Just John

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #226 on: February 06, 2020, 10:27:04 pm »
I would run the ARD. Nice job on fitting the pipe. The new mount looks much cleaner.
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Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #227 on: February 07, 2020, 02:31:59 am »
Thanks John, that might happen, depending on how long it takes to put the 1428cc engine together. I've started wiring it today, and what a nightmare! Not having an electric start or charging system means I really only need enough wires for ignition and lights etc, but there are wires going everywhere, and while Kawasaki was nice enough to supply some big multi pin plugs to make life easier, their color coding on other single wires is awful, and at the moment I have wires going in all directions, so I'll have to do a google search to see where all that stuff is supposed to go.

Only good thing is all the wires are new, so no dodgy old wiring to throw a spanner in the works. Hopefully tomorrow, I'll have enough done to do a quick lap around the block. Wish me luck! ;D

 
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline BPellerine

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #228 on: February 07, 2020, 07:30:29 am »
Bill how long does it take to set the points ?
 Is there more room under the Webers ?
hi frank,I set everything up on the mag before I put it on the bike,so was not hard,no1 cyl at or near full advance using a stock advance unit to get positon,then set mag with rotor button pointing at no1,then put both pulleys on together.bill
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another anfob

Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #229 on: February 13, 2020, 01:03:23 am »
Wow, I can't believe almost a week has gone past since I last posted, but fear not dear readers, I've been working hard making stuff work. In 2018 when I first bought the bike, my intent was to give it more of a Z1 looks, because basically (without insulting Z1000 folks) the Z1 is just a cooler looking package. I ordered all Z1 bits mostly, so of course there were a few issues making Z1 stuff work on a Z1000.

Of course, being a custom, I also had to modify stuff. I decided not to use Z1 (or Z1000) headlight ears, just because I don't like them much, so I bought some alloy aftermarket items. The blinker stalks mount to the frame and OEM headlight ears by way of a diamond shaped casting on the back of the stalk sitting on a specially cast rubber grommet which worked well on the stock rear mounts, but were no good on the aftermarket headlight ears, so I chucked 'em in the lathe and machined a few mm off then slice the rubber in half. 

Zed blinker base mod by Terry Prendergast, on Flickr

Zed blinker base mod 1 by Terry Prendergast, on Flickr

Zed blinker base mod 2 by Terry Prendergast, on Flickr

The hollow threaded tube wasn't long enough so I decided I'd just drill out a couple of 10 x 1.25mm bolts. What a PITA that was! It took over two hours, and I had to sharpen the drill bits several times! Anyway, it worked out, and I now have front blinkers.

Zed blinker base mod 6 by Terry Prendergast, on Flickr

The next problem was mounting the gauges. I prefer the Z1 gauge/idiot light panel, but the bracket doesn't fit the Z1000 top triple. Genuine Z1 top triples are like Sandcast parts price wise, so I sold my left testicle to buy a nice re-powdercoated Z1 top triple from the US, hoping it would mate to the Z1000 bottom triple, and luckily it did. I did try to bodge it using the Z1000 top triple and a piece of the Z1000 gauge bracket, but it just didn't look right, and as much as I'm not even close to being a perfectionist, it pissed me off, but I'm much happier now.

Before:

Wednesday Zed wandering 12 Feb 2020 by Terry Prendergast, on Flickr

After:

Wednesday Zed wandering 12 Feb 2020 1 by Terry Prendergast, on Flickr

I scared the bejeezus out of myself last night when I'd (roughly) wired it up and kicked it in the guts. It fired right up, idled beautifully, and then this happened!

Spotty came over to collect a few gallons of my last batch of ginger beer (I haven't heard from him since, I hope he's ok?) and we mulled over a few possibilities, but in the end it was as simple as the idle speed adjuster screw somehow coming out and jamming behind the throttle cable cam. I suspect there's a spring missing, but for the time being, it's fixed, and the bike starts first or second kick, and idles beautifully, which is pretty good considering I haven't cleaned the points or replaced the plugs.

It also snicks into gear nicely, butt doesn't like going back into neutral, although I haven't actually ridden anywhere and the 15W-50 oil I put in it was still cold. I do suspect that the clutch does need a finer adjustment. Anyway, no biggie, it's looking good, it's nice to sit on, itt runs well, sounds great with that new Delkevic pipe, and hopefully it'll be a fun ride. With luck, I'll find out on the weekend. ;D

Zed blinker base mod top triple change by Terry Prendergast, on Flickr

     

 

     
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline PeWe

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #230 on: February 13, 2020, 09:18:04 am »
Good progress Terry!
You got the gauges right.
I'm sure many will see this as an old stock bike with a 4-1.

Z1-900 color scheme of your favourite choice would be perfect, right?

Offline mrbreeze

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #231 on: February 13, 2020, 11:08:13 am »
Reminds me of my 1000LTD Terry. I've been searching for one lately and they are getting hard to come by.
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Offline Tintop

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #232 on: February 13, 2020, 11:21:27 am »
Reminds me of my 1000LTD Terry. I've been searching for one lately and they are getting hard to come by.

It was wire wheel 1000LTD rear disk hubs that were used on the front & rear of my old sidecar.  I picked up x3 wire F rear disk hubs to build for another set, but still in a bin.
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Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #233 on: February 13, 2020, 11:47:37 am »
Thanks guys, all comments are gratefully received! Yep, as per my original plan, this is a multi-phase build.

This is phase 1, to get it on the road, then I'd like to do better (modern) forks, wheels and suspension, then paint, then the big 1428cc engine.

Of course priorities change, I may not do a lot more to it soon, except skipping across to the big engine, as I've now secured a welded and balanced crank, Z1 head with big ports and massive cams, gearbox guts, clutch. Etc.

I also bought a set of 40mm Mikunis with K&N pods cheap, because one of the float towers is busted. I must try to find a laser micro-welder locally who can fix that for me, or just mix up a little JB Weld, I'm told it works fine immersed in fuel, once cured? The head came off an MTC 1327cc big block engine, so hopefully the combustion chambers and cams won't require too many more mods to make them work with the Arias 1428cc pistons.

I've also got a good used crank for my 1973 Sportster on it's way, so that will be another priority to get it installed so I can ride it after sitting for so long.

I've pretty much run out of bike parts money by now too. And as I've just signed up for "The long ride" to raise money for prostate cancer in October, I'll just have to go with what I've got project-wise, but if I'm riding the big Zed, the old Iron Head Sporty and the Yamaha 650 by Christmas, it will have been a great year. ;D

I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline spotty

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #234 on: February 13, 2020, 06:24:20 pm »
fear not, i'm alive and well, had CFA meeting on wed night which should have been a sober affair but it was at the auxiliary presidents place and she likes a drop of wine so the 3 of us called it a night after a bottle each ( i do like good champagne ) and then last night was fix the hot water system at the old house and then bike club meeting in s.melb so it ended up being about a 140km drive home after work....

rest assured i shall be quality testing the ginger death juice this weekend, maybe after a visit to newport for a 2 yo b/day party, i should need a drink by then

glad the WFO throttle was something so simple and good luck taking it for a blat this weekend
It seems I've kicked the Honda habit again...anyone mind if I stick around ?

Offline 754

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #235 on: February 13, 2020, 09:21:18 pm »
Terry you Freaking Savage...can you not use an aluminium or cardboard shim while  holding chrome parts in the lathe chuck. .
 THE BOLTS ..2 HRS REALLY just make the bolts in less time, or make threaded studs and a nut..
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My next bike will be a ..ANFOB.....

It's All part of the ADVENTURE...

73 836cc.. Green, had it for 3 decades!!
Lost quite a few CB 750's along the way

Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #236 on: February 14, 2020, 02:04:29 am »
Ha ha, it's a "Mad Max" bike Frank, not "Fancy Frank". lt's supposed to be rough around the edges, and the disappointing thing is that it's actually a lot tidier than I originally intended! Oh well, it's a "forever" bike, so I guess I'll make it look rougher with every incarnation. Looking forwards to receiving all the bits for the 1428cc engine, now that's gonna be a lot of fun! ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline PeWe

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #237 on: February 14, 2020, 06:00:22 am »
The bike look really good Terry!

You will gather lower priced parts making it possible to transform it to a stock bike for good sell that day it might be actual?

Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #238 on: February 14, 2020, 03:40:50 pm »
The bike look really good Terry!

You will gather lower priced parts making it possible to transform it to a stock bike for good sell that day it might be actual?

G'Day Per, I don't think it'll ever be a "collector" bike because of the mods I've made, and really, to me at least, it looks way better in it's current form that a stock KZ1000. My intent is to keep it forever, and my two boys (who both really like it too) can decide what to do with it.

I am starting to have second thoughts about the 1428cc engine. Rather than pull this engine out and park it in a dusty corner of my garage, why not build another big Zed bike around the bigger engine? I got onto a guy who wrecks bikes, really nice guy and well priced, (but totally unreliable) who said he might have some spare frames, so if another one (preferably a Z1) came along, well, it'd be too good an opportunity to pass up.

I might have to sell some of my other projects to finance it which pisses me off because I love all of them, but I have been promising to thin the herd for the last few years, and that hasn't happened at all, in fact it's just gotten bigger. Maybe sell the spare RC51? They're becoming quite collectable now, so I should get some good money for that one from someone looking for a cool track day bike? I can't sell the good one as I haven't ridden it since I lost 150 pounds and want to see what it's like now, but the crashed bike would probably pay for another Zed build, and make someone happy?

Anyhoo, warm, wet and humid outside today, so going to concentrate on tidying up some minor things on the Zed before I take it over to Jeff at Ace for a Roadworthy inspection next week. Then maybe a little "test ride" to make sure nothing falls off before the inspection. More later. ;D
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline PeWe

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #239 on: February 14, 2020, 10:52:18 pm »
I was almost right then ;) collecting parts... but here for another build !! :)

It is risky to have parts on the shelf...ideas about build something with them start a domino effect.

I found an old ported early K2 head 7-8 years ago. Refurbished it last year giving it my old not much used valves, port job upgraded on all ports, seats for the 34mm in valves.
Then idea about my 900cc  cylinder. Found complete crank and gearbox from an F2 on eBay.  K2 1975 case and all other engine parts from a friend nearby. Super rods on its way.

No empty frame to put it in, might do if finding a bike with shot engine.

Another alternative is a Z1-900 in ugly 80 style modified shape they want 5000 USD for. 4000 sounds better so I can.drop at least 7000 more for parts on it making it to look good again.  My garage is too small.

Offline seanbarney41

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #240 on: February 14, 2020, 11:59:06 pm »
PeWe, you got that #$%* right.  Today, I could buy within a 6 hour drive of me...one cb750f2 with original paint, 6 kz650's, 2 amen saviour cb750 frames, 1 kz1000 amen saviour frame...all for about $3000 total, hook up the trailer to the van and go for a drive of about 14 hours total...really gotta stop and think about what you really want
If it works good, it looks good...

Offline PeWe

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #241 on: February 15, 2020, 12:15:47 am »
That was a good package!
You will regret not bying it?
In that case possible to sell some of it for payback funding restore.

The market of old bikes from the 70's  for not that much is really big in USA.
I was very close to buy a green stock Kawasaki Z650 -76 when I found my K6 early 1979.  They look really good. The upgrade and rebuild possibilities of a CB750 won.

Here some people think that an old rotten out CB750 in need of parts and machining for 8000-10.000 USD is worth 6000-7000 USD. Many  mods at the late70's early 80's cost a lot to undo ;)
« Last Edit: February 15, 2020, 12:21:59 am by PeWe »

Offline seanbarney41

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #242 on: February 15, 2020, 12:47:16 am »
Yeah PeWe, it is utterly ridiculous in the midwest of the U.S. right now...the stuff is nearly valueless unless you can somehow get it cheaply transported anywhere else,  there is just so much...my home garage is full, my shop is full, even the 2 upstairs bedrooms of my house and half of the kitchen...!
If it works good, it looks good...

Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #243 on: February 15, 2020, 01:53:02 am »
Ha ha, yeah mate, it's a sickness, but I'm not really worried about finding a cure, when I run out of money I'll start thinning the herd, to fatten my bank account. I've seen some later model Kawasaki's that have had the Z1 treatment and don't look too bad? I had a 1982 Z750L2 that I swapped a bicycle and some cash for in 1989 or 90, it was an ugly square thing and really didn't like it much, so after I restored it and rode it a couple of times I traded it in on a Ducati 900SS (Bevel Drive) which was beautiful, but mechanically a POS from the factory. Modern dukes are good, but the "classic" 1970's bikes were rubbish.

Anyway, what a disappointing day it was today. Cold, wet, and generally miserable. A good day to work on things that don't require being out in the weather, First problem is that the Yamaha FJR1300 front brake MC doesn't have a threaded hole for a mirror.

Saturday Zed therapy 15 Feb 2020 by Terry Prendergast, on Flickr

So I made one. And what a pain it was, You'd think an internally threaded plug for the mirror mount to thread into would be easy, but it took a couple of hours of trial and error until I had it where either it didn't rotate (rotating mirrors don't work very well) or whether the brake lever didn't want to be partially seized when I tried to tighten it to stop the whole plot from rotating. I ended up drilling and tapping a 3mm hole for a screw in the base, then a corresponding hole in the MC to lock it in place.

Saturday Zed therapy 15 Feb 2020 1 by Terry Prendergast, on Flickr

Saturday Zed therapy 15 Feb 2020 2 by Terry Prendergast, on Flickr

Anyway, I've now got mirrors.

Saturday Zed therapy 15 Feb 2020 4 by Terry Prendergast, on Flickr

As much as I like looking at my home brewed rear brake setup, I had some Z1 replica sidecovers which of course don't fit Z1000's without some modifications, so I did some modifications, and was pretty happy with the end result. I haven't quite finished "finessing" them into place, but you get the idea.

Saturday Zed therapy 15 Feb 2020 5 by Terry Prendergast, on Flickr

Anyway, tomorrow I wanna install the other sidecover, clean up the wiring a tad more, and take it for a lap. Hopefully the gods will smile down upon me and I'll have a great ride, and won't get busted, or die in a bloody pile. We'll see. ;D

Saturday Zed therapy 15 Feb 2020 6 by Terry Prendergast, on Flickr   
 
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline PeWe

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #244 on: February 15, 2020, 06:38:37 am »
Number matching on side covers too ! :)

Offline Tintop

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #245 on: February 16, 2020, 09:22:07 am »
So?  Road test report.  That's if your not in jail, or if you are, have internet access. ;D ;D ;D
1977 CB550/4 Cafe - Speed Warrior / BOTM 03/11
1980 CB750F (project)
Whittaker GBF Vintage Racing Sidecar (XS750 power) - ITG / 151's / CMR Racing Products (SOLD)
1976 CB400 SS - stock / BOTM 04/11 (SOLD)
1973 CB750 K - basket case (SOLD)
77 CB550 Cafe build
550/750 Filter Thread
Sidecar Rebuild Thread

Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #246 on: February 16, 2020, 12:48:26 pm »
Ha ha, well I wasn't happy with the sidecover mounting brackets I'd started to make on Saturday, so spent all day making new ones, which fill me with confidence now, the old ones were nowhere as secure.

By the time I'd done that, tidied up some wiring. (Still have lots kf wires that need connecting, but can wait until I have an operating charging system, it was time to come inside and drink alcohol.

If the driveway is clear tonight after work, I'm gonna do a sneaky ride, not having ridden this bike yet is killing me! Don't worry, I will take pics......
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline Terry in Australia

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #247 on: February 19, 2020, 02:39:40 am »
Well it was the best of times, it was the worst of times. Hmmnnn, that sounds like there was something really bad, and unlike Charles Dickens' "A tale of two cities" from where I "borrowed" the quote, things were actually not too bad at all. 

Yes dear reader, after a couple of false starts, on Monday, I finally got the big black mamba out on the road. I was dithering between spending 56 bux for an "Unregistered vehicle permit" which legally allows me to ride the bike on the road (within limits) and just putting a number plate off another bike on it and hoping that the cops don't pay too close attention to me. The older I get, the bigger chicken I've become so I paid the dough, but the other benefits are manifold, particularly if I'm involved in an accident.

OK, so document in hand, or at least in my pocket, I fired up the old monster and took off up the street. "Monster" is a good description, because, as much as I've "Streetified" it, it still has the heart of a drag bike, and is not happy unless the throttle is being held wide open. I don't mind that, I never wanted to turn it back into a stocker, but it made me nervous on my first ride, which involved significant traffic flow, being after work on a Monday afternoon.

A few observations: The front forks are horrible. I think I mentioned when I rebuilt the forks that the springs appeared to be "heavy duty", perhaps to stop them collapsing when the front wheel came down after a wheelie. They'll need to go, every speed bump was a "pile driver". Luckily the rear shocks were fine.

The rear brake doesn't work, at all. It felt fine when I first hooked everything up, but I'm guessing there was a massive air bubble inside the caliper or line. There are no leaks, just no brakes either. Luckily the front Brembo's are magnificent, accompanied by the used FJR1300 MC and chinese braided lines, they felt positive, powerful, and had plenty of feedback, so while I was juggling with no rear brakes and a dragging clutch (more on this later) in peak hour traffic with an engine that didn't want to just idle along merrily like a stocker, at least I could pull up quickly, and with those hard front springs, no notable fork dive if I had to grab a handfull. Oh, and the gearing is way too low, 60 MPH @ 6-7000 RPM in 5th gear (guesstimate, I just received my electronic tach from Nic today, so I'll install it on the weekend) is way too low. I've ordered a much smaller rear sprocket. I could have ordered a bigger front sprocket, but there's no spare chain, and even though I have some spare new 530 chain in my garage, I didn't want to install another joining link, one is enough.

Anyway, once I finally got past the traffic, I opened the taps, and it rocketed forward, woohoo! This thing has got some real grunt! Being that the gearing was so low I didn't dare take it past 80 MPH on the speedo. I'dd just overtaken a line off cars and was starting to feel pretty relaxed, when suddenly, the engine died. Fark........ As you all know the bike has no recharging system, so electrickery was my first concern, but no, all the lights and blinkers, horn etc seemed to work fine, just no power to the coils. Bugger.

Now a smart man would have taken tools, insulation tape, cable ties, a test light, etc, but no,remember this is me we're talking about, so all I had was a plug spanner and a pair of pliers in my jacket pocket, that have probably been there as long as I've had that jacket. After a long time (maybe an hour) I discovered frayed rear blinker and tail light wires, where the wires pass thru the aftermarket "Rear fender eliminator. Not having any insulation tape I disconnected them from the harness and kicked it in the guts, but no dice. Bugger.

I'd by this stage removed the tank and sidecovers, so I just kept tracing all of the wiring, until I found that the wiring on one side of the multi wire plug connector for the lights/kill switch had all melted together. Well that made sense. OK, so eventually, I disconnected everything, pulled a couple of earth wires I'd made for the rear blinkers and hotwired it, twisting one wire around the positive wire connection on the coils, and the positive terminal on my battery, and one from the earth point on the coils back to the negative terminal on the battery. It fired right up, so I put everything back on, and rode home slightly stressed, slightly sweaty and smelly, but happy that I got home, and not on the back of a tow truck.

The weather has turned back to crap over the last couple of days, but once the sun is shining, I'll get back out there and fix that wiring, hell, I might even wire in a fuse or two. (yes, there is a fuse box, but because there's no regulator or starter motor, the fuse box isn't actually connected to anything.) Anyway, here is the only pic I had the presence of mind to take.

Terry's big black Zed's first ride 17 Feb 2020 by Terry Prendergast, on Flickr

Oh, and the good news is that some big boxes have arrived over the last couple of days, so the crank and other parts for my 1428cc engine have arrived, I'm looking forward to putting it together, but that's another project......... More later. ;D             
I was feeling sorry for myself because I couldn't afford new bike boots, until I met a man with no legs.

So I said, "Hey mate, you haven't got any bike boots you don't need, do you?"

Offline PeWe

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #248 on: February 19, 2020, 08:24:28 am »
Good news, Terry!
Mostly small adjustments to a rideable bike.
Melting wires, connect fuses reducing the damage when the electrics goes bad, fork springs with eventual oil level. Rear brake adjustment.

Maybe a  throttle limiter/ life extender too?  ;)

I almost forgot... Steering damper, right?

I had a H4 bulb or maybe a parking bulb that blew the fuse on my K6 when it died.
Cheap bulbs included in a reflector when purchased.  Happy that bike was in the garage.

Online jaytee-nz

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Re: Terry's Kawasaki Z1000 Mad Max Bike, my er, 2020 summer project.
« Reply #249 on: February 19, 2020, 11:14:27 am »
Well done Terry - great to see the big K on the road again.
I restored a 1976 Z900 many years ago and should not have sold it - but you know about those decisions.
Reading your posts is always entertaining, both from a writing and riding point of view !

 

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