Topic: Maui Z1 1973

[jaytee-nz]

I just got my K2 gauges back from Marcel. He did his usual excellent work, but I hope you aren't in any hurry for yours as mine took 5 months to complete.

[Terry in Australia]

Thank God I don't need any done soon......

[ekpent]

 I used to have a furniture repair/refinishing biz and I sure miss the good stripper that used to be around. If I knew the ban on the good stuff was coming around I would have stashed away a five gallon bucket. Might be fun to try a small part or a little section of something with some brake fluid and let it sit.  We all love messing with that nasty stuff    I've read where guys have used oven cleaner on anodized parts,not sure on paint,never tried any or know effect and engine metal..

[RAFster122s]

Castrol Super Clean used to be able to strip anodizing from aluminum, not sure if it still can. You could strip the anodizing from controls (control housings) and either polish them or have them hard anodized then...

[Stev-o]

  I sure miss the good stripper

Me too!  [since I got married]



Sorry Maui, couldnt resist!

[grcamna2]

  I sure miss the good stripper

Me too!  [since I got married]



Sorry Maui, couldnt resist!

Lol !

[MauiK3]

It’s ok, I sort of thought someone would make that leap into the proverbial gutter😆
So today I started removing fasteners to split the cases, I’m waiting for my clutch tool so I’m leaving the large ones in. It’s a little nerve wracking removing the 6mm bolts torquing them up hoping they don’t snap off. They came out ok but I found two missing bolts. I’m glad I’m taking this engine apart, hopefully I’ll catch all the errors. The clutch plates look ok but the springs are heavy duty, I’ll revert to stock, I’m not drag racing and I don’t want to pull on that much spring. If my hold up continues I’ll start breaking down the wheels for new spokes etc. the spokes are terrible, par for the course here. Zinc plated spokes don’t hold up long.

[Terry in Australia]

Good work Steve, and don't forget, when removing rusty bolts, your Mapp gas torch is your friend, I forgot between removing the bolts in my T350 and those in my T500, and I managed to snap one in my frame, so that reminded me and I broke out the torch, and they all came out nice.

Also handy for removing paint. A bit of heat, a scraper and a wire brush, and you're good to go.

[grcamna2]

Good work Steve, and don't forget, when removing rusty bolts, your Mapp gas torch is your friend, I forgot between removing the bolts in my T350 and those in my T500, and I managed to snap one in my frame, so that reminded me and I broke out the torch, and they all came out nice.

Also handy for removing paint. A bit of heat, a scraper and a wire brush, and you're good to go.

Steve,I hope your home workshop has a vent fan   

[MauiK3]

Yes, fans are my friend.
I have a window fan blowing out, a little floor fan blowing on me when needed and there is a nice trade wind usually coming in through the open garage doors. We have lots of steady air movement here on Maui.
When I do really stinky stuff I'm right at the window with the fan in it and I wear a respirator. I have N95 welding approved disposable types and I also have a negative pressure organic vapor mask for really bad stuff.
Of course when I paint I put on a respirator and calm the air down.

[MauiK3]

While I’m waiting for some stuff (I’ll be doing that a lot) I’m going through all the bags of parts figuring out what to clean and keep, what to replace, etc. I discovered today that I have a mismatched set of exhaust header clamps. 3 are early style, consistent with the low engine number and one is the newer style. This gives me 3 choices.
Use the ones I have, perhaps after re-caroming.
Find one early style of the correct handedness ( they are lefts and rights)
Get a whole matching set of new style ones.
I’m leaning toward finding the 4th matching clamp but whether I can find one remains to be seen.
Ugh. I’m trying to keep it pretty original but it’s not easy.

[grcamna2]

Maui,I hope you can find that 4th Early style exhaust flange clamp.
The 2 inner ones in your pic look good.

[RAFster122s]

The heat makes chrome have a tough life. Looks good, keep up the good work...

Need to have a trip to southern California with your parts and then across the border to Tijuana to a chrome shop. Shipping costs are so nuts it might be cheaper that way, if you could get them back via an airline without damage in baggage. SW has been have cheap tickets even to Hawaii...

[Terry in Australia]

While I’m waiting for some stuff (I’ll be doing that a lot) I’m going through all the bags of parts figuring out what to clean and keep, what to replace, etc. I discovered today that I have a mismatched set of exhaust header clamps. 3 are early style, consistent with the low engine number and one is the newer style. This gives me 3 choices.
Use the ones I have, perhaps after re-caroming.
Find one early style of the correct handedness ( they are lefts and rights)
Get a whole matching set of new style ones.
I’m leaning toward finding the 4th matching clamp but whether I can find one remains to be seen.
Ugh. I’m trying to keep it pretty original but it’s not easy.

I presume that they've all been drilled out to 8mm Steve, so none of them are original now anyway, but your chances of finding one original one from someone who'd restored an early Z1 and has some leftovers is probably more likely than finding 4 minty original early ones. (which won't fit on your 8mm studs)

[69cb750]

I’m leaning toward finding the 4th matching clamp but whether I can find one remains to be seen.

The 73/74 clamps are more common then 75 clamps.
https://www.ebay.com/itm/333572610287?epid=1544145500&hash=item4daa7a18ef%3Ag%3AvyYAAOSwOQJekiWJ&LH_ItemCondition=4

[MauiK3]

Still are 6mm studs in the head, I don't think they are drilled out but I'll check.
I looked for some on Ebay but did not see the link you posted , thank you very much.
I think I'll buy them.
There is a chrome shop on Oahu I'm going to check in to, may save me some shipping costs.

[grcamna2]

That looks like a good deal 

[MauiK3]

I ordered them, I’ll have some spares in case any crack.
I spent the morning measuring pistons and bores. As seen in earlier photos, the pistons and bores look great, hone marks in the bores, un-scuffed surfaces on pistons.
Readings were consistent in all cases. I used my telescoping gauge and my 2 to 3 Starrett micrometer.
The conclusion? The previous work setting it up with first over pistons put the clearance with the bores at the top of the tolerance which is 0.0025” to 0.003”. I’m at the top.
I didn’t want to see that but there it is. This bike will likely never see big mileage (Maui is an island after all), drag racing, desert riding, etc. maybe this clearance doesn’t matter that much, I imagine really high mileage bikes go over this limit and run fine all else being equal.
My only option would be to go second over and find someone that knows how to bore/hone one of these without screwing it up so I have to re-sleeve it.
I don’t want to do a big bore, I’m trying to keep it close to stock.
Any Z1 opinions are welcome.
I’m naming this bike the “Wounded Z-1”

[69cb750]

The conclusion? The previous work setting it up with first over pistons put the clearance with the bores at the top of the tolerance which is 0.0025” to 0.003”. I’m at the top.

0.0025” to 0.003” is perfect, they came new this way.

[Stev-o]

The conclusion? The previous work setting it up with first over pistons put the clearance with the bores at the top of the tolerance which is 0.0025” to 0.003”. I’m at the top.

0.0025” to 0.003” is perfect, they came new this way.

+1 run it Maui! Will be good for your lifetime....

[MauiK3]

Great to hear, I was hoping that would be the vote.

I have not checked ring gap yet but the compression was great, a bit high even and very close together,
I think because the ticket for the work done in 2009 talks about decking the head.
I removed my choke plungers to send them to Robert Meggitt for the little viton washer insert repair. My idle mixture screws had little effect when it was running
and I think the choke plungers were the reason.
Has anyone seen a part for the little nylon washer that lifts the choke plungers? Mine work but they are a bit tired. Also the seal cap. I'll do some searching.
My oil pump checks out fine, no scoring, 0.002" clearance. Yay.
This one will also run on 89 ethanol free, don't want to screw up these carbs!!!
Turns out the head studs are over sized, po I guess. I'll leave them in but I'll really check the oil passages, two of the studs are part of the feed to the head. I don't want to risk pulling a thread in the engine casing, too too risky.

[ekpent]

 I liked Frank's nickname for your bike "Maui Wowie". 

[Terry in Australia]

I liked Frank's nickname for your bike "Maui Wowie". 

Gotta love Cheech and Chong............

[MauiK3]

Video of the run!

[grcamna2]

Sounds good Maui.