Well the project train keeps on rolling. Keeps me mentally sane-ish having a project always on the go n distresses me.
Harris`s turn at mo. Had her 13-14 years now and been evolving along the way really. Was my daily transport for many years and been on touring holidays, etc 2-up with luggage. Been everywhere really in all weathers. Few bits been updated over the years as they’ve worn out or I`ve come across them cheap, etc.
Z1B lump, 998cc overbore, raised compression, welded/balanced crank, new/old stock head with light polishing, stainless valves, kent cams, 29mm carbs, etc, etc. Pulls like a train for an old girl. Enough grunt to keep me happy anyway. Love this bike to bits n probably be buried with it. Lol.
Before strip down. Looks ok but was a bit rough close up n a lot of bits I wasn’t happy with finish of, etc. Looked like a rat-bike compared to my tubby bandit so time to pimp it up a bit. :-
Drove it onto bike bench 2 weeks or so ago n started pulling it apart. Few rusty bolts n usual crap with an all-weather bike. Got to this stage and couldn’t get last engine bolt out.:-
2` stainless bolt passing through (2x) 4” alloy frame spacers was stuck solid even though copper greased it to death last time it was out years back.:-
Got a hacksaw blade into gap between engine and frame and holding blade in my hand I could wiggle it up n down ½” at a time only. 2 evenings were spent out there on my knees sawing away at it. Lol. Chopped through it and then with a sledge hammer in one hand and a drift in the other I spent 3 hours hammering away at the 2 halves till eventually came out. Feckin solid! :-
My mate Emoe from Haydencycles knocked me up a high grade stainless replacement for when goes back together. Bike wont be seeing same winter weather nowadays so should never get as bad again.:-
A lot of years of bare alloy engine and living 50` from sea and the engine was a mess in areas I couldn’t reach to clean normally. :-
Solid crud too. Built my own soda blaster and wouldn’t even touch it. Tried spraygun cleaner (100% solvent) and didn’t touch it. Only thing that shifts stuff between fins was a small screwdriver and lots of hours. Degreased whole lump to start with anyway. :-
Got 2 cans of Mr Muscle oven cleaner sitting here and buying a powerwasher tomorrow (which I needed anyway) so should be able to get it cleaned up and sprayed shortly.
Was over mainland other weekend on my trike getting its mot n doing a bike show. Came back with these parts for it for free off some good mates. :-
Old forks were bin fodder. Top halves were pitted to death, bottoms had cracks around seals, inside bushes, etc shot too. Useless yet bike still handled really well on these twisty mountain tracks.
Off a TZR250 reverse cylinder import model. Wasn’t sure about them seeing as theyre off a smaller bike but theyre just as big as gsxr ones and make my 80`s original ones look like toothpicks. Lol. Twice as stiff too so should be fine. Harris is a lightweight bike anyway so these should be a vast improvement over old ones. Same length too which is a bonus.
Pitting on lowers is about 5 spots this size. :-
Cant feel them and need a magnifying glass to find em so Im happy. Good change of seals n oil, etc and should be fine. Free is my favourite price.
Wheel spindle is off something else but fits threads. Needs a spacer one end as slack in fork leg end.:-
Have some nice billet risers already on too. Was planning on clip-ons but with my t-rex stubby arms straight bars are much better option. Probably make some billety ones same as my bandit for it as really like the look/feel of them.:-
Drifted yoke stem out of old yokes yesterday and brought forks/wheel/spindle in house to get a proper measure up. :-
By pure chance the wheel spindle fits perfectly in wheel bearings which is a bonus. :-
Bit more wheel/disc clearance than old forks too.:-
Measured up for spacers for top/bottom yokes, fork leg end and wheel spacers. Got a mate sending me some bar scraps up to make them out of. Got a wee lathe in shed so should be able to turn them all up myself.
My wife spent several days with wire brush on the grinder/drill buzzing back the frame. No blasters or anything on my island. Everythings a PITA to do up here as have to do everything yourself. About 10 layers of smoothrite and aerosol paints, etc. Just chopped off the rusted in bolts and drilled/ re-tapped few holes, etc so ready to go.:-
Underneath paint is flaky nickel coating with a fair texture to it. Painted over it several times over the years with no problems so not worried about it. Main thing is getting a smooth finish this time as has always looked a bit crap in brush painted finish to hide the roughness and edges of plating. I spray for a living these days though so do it properly this time. Several layers of high build primer and smear of filler if needs be to smooth out roughest edges and should come up smooth. Planning on metalflake finish anyway so any small flaws will be lost under good 1mm+ of flake. lol
Got frame in sitting room this afternoon scraping n chipping out last of paint from corners and recesses. Thankfully my wife doesn’t mind bike bits everywhere. lol
General plan is keep the same general look as love the way it is, just finish everything better. Go through each piece and re-work it in same way as I did with tubby bandit really. Remake most of alloy parts to a better /neater finish. Engine silver with black gloss cases. Homemade belt driven alternator up one side using some toothed belts/alloy gears I had sitting about. Sorta like this.:-
Tuck that bandit alternator I picked up into gap by carbs.:-
A matching setup on other side of bike with a belt driven mag looking setup (more to come on that). Carbon fibre guards with of some sort for them both. Few carbon fibre detailing pieces here n there.
Clutch casing on mine is cracked n knackered so going for a 80`s endurance style of lifter setup as love the look of them.:-
General red/black/silver colour scheme and detailed to death with lots of home-made parts as Im a tight-ass womble. Lol. Paintwork wise I`ve got paintscheme worked out in my head already. Lol. While away before get to that stage though. Try push the boat out n do something really wild on it.
So yeah 2 weeks in and updates to follow when get summit done really. Not in any huge rush as want the end result right. Doing an hour a day or so, so things will keep chugging along.
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Originally Posted by Gitzy
Hopefully I`ll do an alright job bud.
