Topic: Terry's new Kawasaki Z1B build, the OCD special...........

[grcamna2]

Kill switch on your bike to crank it without starting.

Possibly consider removing the plugs and laying them on the head and then crank it over w/o the compression of the plugs installed for faster oil pump pressure check?

This will allow the engine to spin over faster to achieve oil pressure while using only the electric starter.

[Terry in Australia]

OK, so I missed getting it inspected today (slept in) but I did get it about as ready as I can. Before I did the valve clearances (which are all a bit loose as I don't have enough of one or two particular size shims, but at least they're not too tight, so not too fussed) I thought I'd crank it for Steve so we could see if the oil pressure comes up just by cranking it.

Yes, my poor old eyes aren't too good, I thought I saw the needle come up to 3 psi, when in fact it was only about 1.5, but still, I was able to answer Steve's question.

[MauiK3]

Thank you!!
Now I know what to look for eventually.
I bought a new oil filter bolt to modify as an air fitting to track down all the places air goes from the filter up, I may have to split the cases again to check all destinations but If I have to I have to.
Many thanks for all your help.

[grcamna2]

Steve,I think this may be redundant but are you pleased with the clearances between the cam caps and camshaft after final torque ?

[MauiK3]

Yes, they are ok. In actuality, if you have stock caps matched to the head, cams that are in spec, and new bearings, they (clearances) are fine. Since there are no + or - bearings your fitment options are limited to perhaps loosening the fit if needed. Making sure it spins well after bearings are assembled is a good idea because it IS possible to get a bearing installed out of place. The cams are pushed up by the valve springs and held down by the bearings and chain tension. I think it’s like a walking wobble (tiny amounts) as the cams rotate through the valve sequence. I’m not sure why my particular engine has the problem it has but I’m not done looking, more to come.
Many apologies to Terry for this thread hijack. This forum is what has helped me over my frustration with my Z1 project.
Thanks to all

[Terry in Australia]

No worries Steve, we’re all as interested in finding out what’s going on with yours as you are. I broke down last night and bought a used ‘74 Z1-A head and cylinder block for my ‘73 Z1 engine as apart from a lot of corrosion the head was in good condition with no busted fins, and also came with cams and top chain tensioner.

I’m gonna build a stock engine out of it as a spare for my Z1-B at this stage, but if a Z1 frame comes along, it’ll be the start of yet another project……

[MauiK3]

Oops, bike and project count not going down eh?

[Terry in Australia]

Ha ha, well I keep telling myself that once the warmer weather arrives I'll start selling some bikes and projects to begin the "Herd-Thinning" Steve, but regardless, the Z1, K0, Rocket III, Sportster and Suzy T350 are all keepers, so it doesn't matter if I spend some more money on them.

[PeWe]

That's how a bike project starts!
Vital engine parts on the shelves and maybe a complete tank, cover set. Find all missing and complete the engine.
Next to keep eyes open for a frame.
My brown K2 started like that.

I have another CB750 K2 in the making that will be a mixed build with K4 tank and maybe K6 gauges.
Or if I manage to restore an old set of gauges with the faces, glass and top covers I have, K2 top yoke is needed.

I saw a registred frame for sale 2 years ago and could not resist.
Got a cleaned set of K6 carbs in parts for $125US at the same time... Maybe bike will get VM29 carbs from my shelf.
I have most parts, but the remaining will cost some.
I have 2k rattle cans for frame , swing and the other small parts. Need to do before winter.

[Terry in Australia]

Ha ha, thanks Per, sadly (or maybe luckily for me) Kawasaki only made around 80,000 Z1's from 1972-75 so unlike CB750's, there aren't a lot of spare frames lying around. Of course that's exactly how this project started, I paid a small fortune for a bare Z1-B frame, and built a bike around it.

It's incredible to think that the money I've spent recently on just a bare Z1 engine (crank cases, outer cases, cylinder block and head) have cost me more money than I paid for my BMW R1100RT and my CBR900RR Fireblade combined! Luckily I have a good Z1 crank in a box in my garage, so now I just need a complete gearbox, clutch, pistons, oil pump, gaskets etc, and I should have a good engine if my hotrod engine ever lets go.

I think I'll have to build a stand for it so I can display it, apart from the CB750 engine it is probably the best looking Japanese engine ever built, IMHO.

Yesterday I set the valve clearances, they're all on the "loose" side, because the shims come in increments of .005", so whereas the perfect clearance for a Z1 with big cams is around .005", mine range for .006" to .010" because I need some shims, but hey, that's gotta be better than running them too tight. It was quite pleasant in my "winter workshop".

Z1 Saturday 3 Sep 2022 by Terry Prendergast, on Flickr

I also removed the "1100" badges and replaced them with the "900" badges, because apparently the DMV frown on hotrod bikes, so when Jeff asks me how many cc's, I'll just tell him that it's a Kawasaki 900 and I won't be lying, right?

Z1 Saturday 3 Sep 2022  1 by Terry Prendergast, on Flickr

That pic came out a bit strange to my eye, the sidecover is a glossy black, but I've noticed that my IPhone's camera seems to get confused when I take pics in the patio, something to do with the light coming thru the trellis? Weird. Lastly I had nowhere to mount the horn due to the oil cooler and steering damper, so I just found a convenient bolt on the front of the bottom triple. Not my favourite spot, but it will do.

Z1 Saturday 3 Sep 2022 2 by Terry Prendergast, on Flickr

I can't think of anything that it needs now so I'll ring Jeff and see if he can do the inspection next Saturday, and with luck, it'll pass. I then have to send the paperwork to my club plate guy, then send it to Vicroads (I don't think I have to take it in personally?) and eventually I'll get my red plate and logbook, and I'll be able to do some decent rides. No big rush, waiting on the new RK 630 chain and YSS shocks, just to make for a nicer ride.

[simon#42]

That horn looks like it is going to get very close to the mudguard when you brake terry

[PeWe]

A Z1-900 is something really extra.
I visited a bike and car meet recently. We were 7-8 guys on CB750's parked beside each other.
A Z1-900 in mint stock restored condition, was parked 25 meters away. The CB750's looked small after seeing the Z1 that is a very desired bike.

Your project might return the investment at a future sale.

[MauiK3]

I love the fork brace, very nice.

[Kelly E]

I love the fork brace, very nice.

Me too, I would like to find a decent fork brace for our 77' KZ 1000 LTD.

[simon#42]

I love the fork brace, very nice.

Me too, I would like to find a decent fork brace for our 77' KZ 1000 LTD.

Me too , what make is it?

[Alan F.]

Great news Terry, best of luck with your Roadworty.

[Terry in Australia]

Thanks guys, it's all about the photographic perspective, there's actually 3 1/2 inches (85mm) between the horn and the top of the fork brace, (which I think I bought from an Ebay seller in Britain, but it was so long ago it's no longer on my "purchase history") so unless it's a massive panic stop, I think I'll be safe. 

Per, you're right, I rode my K0 last weekend then when I got home I jumped on the Z1-B and was surprised at how physically bigger it was. As opposed to a CB750, you sit "in" a Z1 rather than "on" it, so it's easy enough to maneuverer around at slow speeds. The prices of these things is crazy, recently I saw a mint survivor Z1-B for sale on FB, I was really interested in it because it was sold new from the Kawasaki dealer in my home town, so in 1975, I probably got told to get off that bike because I was always haunting all the bike shops in town, back in those days.

The seller had only needed to install repro pipes and a seat cover I think, and he wanted $38000 AUD ($26K USD) for it. The ad disappeared after a couple of days, so I'm guessing that he got it. I've probably got less than half of that in mine, so I guess it's an investment, not that I'll ever sell it.  

[Terry in Australia]

The weather yesterday was pretty crappy, so as I had a busy week with lots of bike parts being delivered, I decided to install the new RK 630 chain and YSS rear shocks.

Z1 Saturday 24 September 2022 1 by Terry Prendergast, on Flickr

The rear shocks on a Z1 are part of the iconic design of the Z1, arguably the most beautiful Japanese bike of the 1970's, so I really thought hard about replacing them, but like all shocks of the era they're rubbish, and the repro's, although new (so not full of rusty muck like an OEM set would have after 50 years) are still rubbish.

Z1 Saturday 24 September 2022 by Terry Prendergast, on Flickr

I'd love for Ikon to make a set using their 7610 series shocks with the Z1 covers with reflectors like the OEM shocks, but they don't, so I looked for a set of YSS gas/hydraulic shocks, which are really good value for money, well made, and look good. I already had a set on my Z1000 (KZ1000 in the US and Canada) and like them, so they were the shock of choice. The price was about half what I'd pay for Ikons, with free shipping from Italy so I was a bit worried that it was a hoax, but I was happy that they sent me the tracking details a day or two after the auction, and the shocks arrived in a timely manner. They were easy to install, and apart from having to cut a notch into my plastic chainguard to accommodate the lower most spring, which runs very close to the chain, they're a good fit, and look good.

Z1 Saturday 24 September 2022 4 by Terry Prendergast, on Flickr

The RK 630 O Ring chain looks really good. I was a bit worried about the new chain that I'd bought from Cruzinimage as it appeared that it's already stretched after only doing around 40 miles of "laps around the block" as the bike isn't registered as yet. I particularly wanted a chain with a joining link, and was a tad disappointed that the link that came with it is the rivet variety, which of course makes it an endless chain once it's rivetted in place, so I used the clip style joining link from the other chain, and I'll try to find an RK clip style joining link. I had to cut 10 links off the chain which pissed me off as the chain was advertised as having the correct amount of links for a Z1, but it didn't take long, and I'll add it to my useless leftover chain piece collection.

I bought this chain alignment tool off the interweb and was immediately pissed off that the steel rod didn't fit in it's slot on the alloy casting, so had to drill it out slightly which almost fcuked it. Once I sorted it though, it was sort of interesting to see it clamped to the sprocket and watching the alignment change as I tightened one chain adjuster, and then the other. I've seen better (or at least, more expensive) tools with laser pointers attached, but this thing seems to do the job, although a longer rod would be better, if I can find one.

Z1 Saturday 24 September 2022 2 by Terry Prendergast, on Flickr

I had to adjust the chain a little bit after installing the YSS shocks as I dropped the bike off the centre stand and sat on it, and the 1 inch of free play that the chain had whilst on the centre stand had disappeared, so I backed it off a half turn of the chain adjusters, until I had an inch of free play while I was sitting on it. Anyway, it was good to get that work done, and hopefully Jeff will be back at work soon so I can get my roadworthy certificate inspection done, and get this monster on the road.

I was gonna say "Back on the road", but as I built this bike completely out of parts from many donor bikes and new OEM and repro parts, it's never been "on the road" before as an actual bike. Whatever, I'm looking forward to riding it.

Z1 Saturday 24 September 2022 6 by Terry Prendergast, on Flickr       

[PeWe]

Almost ready for legally riding it.
Terry, I guess this bike will become your favourite bike to ride. If you can handle the throttle careful enough

I'm convinced that the raw power and sound of a tuned Kawasaki will encourage your inner wildness!

[Terry in Australia]

Ha ha, thanks Per, yes it will be difficult for me to ride it legally. As a backup, I'm building a stock Z1 engine to throw in it if it's a bit too scary.

[PeWe]

I'm sure your spare engine will be even wilder (better)

[Terry in Australia]

Thanks mate, no this is a 1973 engine, so worth big bucks (I paid around $3500 USD just for the engine cases, head and cylinder block, plus shipping) so with luck I'll eventually find a 1973 frame that needs a good home, and build a "Jaffa" bike like Steve's, but if not I can sell the engine. The stock 903cc cylinders are in very good condition so I'll just hone them and install new stock size pistons, I have a Z1 crank in a box and a gearbox assembly, so I just need a few things more and I can assemble it. I may never need to use it, but it's always good to have spares.

My other Kawasaki, my 1977 Z1000A will have the 1428cc engine installed, once I get around to bracing the frame and repainting it. Too many bikes, not enough time......    

[Kelly E]

Thanks mate, no this is a 1973 engine, so worth big bucks (I paid around $3500 USD just for the engine cases, head and cylinder block, plus shipping) so with luck I'll eventually find a 1973 frame that needs a good home, and build a "Jaffa" bike like Steve's, but if not I can sell the engine. The stock 903cc cylinders are in very good condition so I'll just hone them and install new stock size pistons, I have a Z1 crank in a box and a gearbox assembly, so I just need a few things more and I can assemble it. I may never need to use it, but it's always good to have spares.

My other Kawasaki, my 1977 Z1000A will have the 1428cc engine installed, once I get around to bracing the frame and repainting it. Too many bikes, not enough time......

What places on the frame are you bracing? My 77' KZ 1000 LTD frame is all sandblasted and I have been wondering about bracing. It's a stock motor and I'm not sure if I need to do bracing. Any tips?

[Terry in Australia]

Thanks mate, I bought a frame bracing kit off Ebay, it contains sheet metal and thin walled tube braces that are welded around the steering head, between the front down tubes, underneath the seat,  (across the frame) triangulating the top frame rails, (like on a CB750) across the bottom of the triangles where the sidecovers mount, etc.

Yep, definitely worth doing on a stocker just as much as a hot rod, I had a professionally braced frame on my gold K2 that won the BOTM thing here back in 2010 and it handled incredibly well. The 1428 will produce double the original bike’s BHP and torque, so bracing is essential if I want to have some scary fun on the backroads. I’ll see if I can find some pics of a braced frame and post them here.

[Kelly E]

Thanks mate, I bought a frame bracing kit off Ebay, it contains sheet metal and thin walled tube braces that are welded around the steering head, between the front down tubes, underneath the seat,  (across the frame) triangulating the top frame rails, (like on a CB750) across the bottom of the triangles where the sidecovers mount, etc.

Yep, definitely worth doing on a stocker just as much as a hot rod, I had a professionally braced frame on my gold K2 that won the BOTM thing here back in 2010 and it handled incredibly well. The 1428 will produce double the original bike’s BHP and torque, so bracing is essential if I want to have some scary fun on the backroads. I’ll see if I can find some pics of a braced frame and post them here.

Thanks