My long termer Z650

[MDM]

Okay, so it's been a long time coming, but I've finally dug through the piles of shite in my shed and uncovered my old Z650.
It's always been a long term project, and it's certainly not going to be completed quickly, so don't hold your breath....
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0002.jpg

[MDM]

Not much room in the Shed of Dread, this is what it's like when everything is put back in...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed - the longest project/IMG_0065.jpg
(And with a new banner put up when I could get to the wall...)

[geesexar]

ya sheds lookin a bit cluttered there but winter is on its way there mate...plenty o time to sort it. Lookin forward to the Z build

[BANDITROD]

yeah bloody oath Dave keep us up to date mate

[ALBI]

get on with it son!!

[Gix11]

Err... 6 years and counting isn't it? You're as bad as me. I also like the fact that it's so top secret we only get to see a dog blanket.

What's up the front there by the way, yea, that one, with the orange tank?

[ozzy1100]

yes but si u can see that it has a turbo what more do we need to know z650 turbo sweet lol

[MDM]

Ha, the shed is a fuck sight less luttered than it was even a month ago!...
And Si, it's a wee bit longer than six years... ahem.
I've found some old pics of when I first bought the 650, and as soon as I get them scanned I'l post them up.
And the bike at the front is Project Procrastinate - you'll hopefully be seeing some more of that in a bike mag near you, soon. Well, I say soon...

[MDM]

And just for you Si, one without the 'dog blanket' (my sleeping bag, I'll have you know!)http://i1078.photobucket.com/albums/w481/MDMSF/morebits044.jpg

[geesexar]

^^^^^fuck yeah

[80s freak]

That's cool. That swinger is nice!

[evad]

IS that a gpz11 motor in it?
Z650 Fan for sure :rolleyes:

[slingy88]

Bloody Great, whats the spec's?

[Dynomutt]

That's got a lot of potential that has Dave, it would be good to see it out on the road finished, whilst yer still young enough to ride the fecker!!! Although you'll probably finish that before I finish me Katana.

[Jockney Rebel]

niccceee one mr manning

[Jockney Rebel]

zxr front end if im not mistzken too

[oldkat68]

that looks the goods,might have to dig my old 650 gs out and give it the once over thats been hibernating for about the same amount of time.

[Gix11]

Are you a sucker for punishment or is that how the tank was when you go it?

What's needed to get it on the road?

[MDM]

Yes evad, that's a GPz1100 Unitrak engine squeezed in. Although it's not in now...
Jockney - yeah, ZXR 750H1 forks and yokes, standard length and handles beautifully. Revalved since I took it off the road, and new wheels & brakes too.
Si - the tank is a one-off by John Williams at the Tank Shop. The standard tank had to be raised at the rear to clear the cam cover, and it looked pantslike that, so I asked John to make me a bespoke ally tank, and he also moved the fuel tap to the righthand side to allow a shorter feed to the carb (yes, singular.)

[MDM]

This lot temporarily on the floor...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0053.jpg

[MDM]

This lot is probably going to be reworked too, partly as there's an additional oil tank to be fitted somwehere, and partly because I'm thinking of using a small battery...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0049.jpg

[MDM]

I gotta find a way to tidy up the top yoke - I don't really like the risers, although they suit the bike as a whole, and I need to get the clocks sorted - the boost gauge replaces the standard speedo, and the standard cable driven rev counter is replaced by an SPA all-singing all-dancing rev counter / speedo / idiot light jobbie.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0045.jpg
The button that I've fitted into the redundant right-hand indicator warning light is the button to scroll through the display on the clocks.

[MDM]

And the catseye rear light seen here is going to be replaced by an SV650 rear light, which fits really neatly under the Z650 'ducktail' unit.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0048.jpg

[Gix11]

I reckon that top yoke could do with a lick of colour mate. The weld looks pretty chunky and will be tamed by the paint, plus the tank being polished needs either the yoke polished or painted (refer to the former!). That battery box does take up a lot of real estate hey?

[MDM]

The yokes may get powder-coated, but that's a decision that can wait awhile, plenty to do before then...

With the old, standard, engine pulled out, the new, trick, engine was slipped into place...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0064.jpg

[MDM]

You might, just, be able to make out that there's a bit of head work been done here...

http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0068.jpg

http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0066.jpg

[Gix11]

How close are those shocks to the rear tyre?

[MDM]

That pic is deceptive Si - the wheel isn't centred (that's the next job), there's actually plenty of room ;)

[ozzy1100]

just a spot of porting lol what size valves did u use ?

[ALBI]

just a spot of porting lol what size valves did u use ?
big fucking ones !!!!

[ALBI]

any chance of some pics of the swinger ???

[MDM]

I promised that I'd post some pics of how the Zed has evolved since I got it, and I found the pics last night and got them scanned today...
As it was when I bought it... bog standard import from the States, original exhaust, single front disc, horrid rear mudguard etc.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/Zedbogstock.jpg
It didn't stay standard for long. Started taking the horrid bits off the day I got it. Managed to find a twin disc front conversion from a shop in Stoke-on-Trent. The 650B1 had a factory option twin disc, so I had to get the second disc and caliper, which was theoretically dead easy as the Z1 had the same deal. Except the Z1 disc was slightly different (thicker, if I remember rightly), so took a bit of finding to get the right disc. The exhaust went in place of a Harris Works Performance 4-into-1, the hooge rear mudguard went and a new little number plate and dinky indicators fitted. Oh, and a horrid tool roll...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/zedtweaks.jpg
Stayed like that for a year, went to the Isle of Man TT etc, and picked up a few more bits. The spoked wheels went becuase I got fed up of twatting by fingers cleaning them, so found a pair of three spoke CMW alloy wheels. I'd also had enough of the marginal braking, even with the twin disc arrangement, so took a trip to see Sweary Bob at Spondon for a pair of discs and some plates to take the GSX-R four pot calipers. New springs and oil in the forks, some Raask rearsets, a ZXR master cylinder and a pair of drag bars.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/zedcmaetc.jpg
It stayed like that for a while, while I was searching for a GPz750 turbo engine. I couldn't find one, and was going to settle for a ZXR750 front end, new swinging arm and 750 back wheel, but then found a cheap GPz1100 Unitrak engine... Took a while to get all the bits, the Z1000J carbs, get the top yoke risers welded on, and wait for the swinging arm (and wait, and wait, and wait). Finally got it all together, with new engine mounts and braced frame by Big 4 Engineering. Fitted some engine bars (don't know why, it seemed like a good idea at the time). New shocks built specifically for this bike by Maxton. Massive exhaust silencer on some aftermarket headers that needed loads of work as they were full of dents and scuffs.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/Zed611.jpg
The Martek swinging arm wasn't finished as I'd asked, and I had to modify the frame so it'd work. But it was lovely in this incarnation, pulled wheelies from tickover, really stable handling too. Made a smidge over 100bhp, if I remember rightly (got the dyno sheet somewhere), and was huge fun until it chewed up the alternator. It was then parked up while I hunted for an new alternator, but then got made redundant and went travelling for three months.
It was while I was in Daytona for Bike Week that I met Terry Kizer, and a plan started...

[Gix11]

Now THAT'S what I call a post! Nice one Dave.

I searched high and low for a photo of my old Z650 when it was matt black and played with, but instead, all I can find is me looking like a tool sat on it in it's original condition when I got it. Thsi would be around '92 I think:

2342


Not the best shot I think you'll agree, but it had the same symptoms you mentioned (except it already had the twin disk set up).

[Gix11]

Correction, I just found a small photo of it after I leant it to a mate for a year to look after. I came back to find the side panels missing and it held together with gaffer tape. I left the UK after that and never saw it again anyway. Wish I had it now.

2343

[hyofighter]

that 650 has come a long way , and a nice bit of work has gone into it , will be checking in to see where this one goes , good luck with it

[MDM]

http://www.streetfighters.com.au/attachment.php?attachmentid=2336&d=1345619492

Not the best shot I think you'll agree, ).

When all I can see is a red X, then yes, I agree! :-)

[Gix11]

When all I can see is a red X, then yes, I agree! :-)

You know, it's pretty lame when the bloke who runs the site can't even put a photo in his post correctly isn't it?

I fixed it, dug a hole, and now I'm going to sit in it and think about what I've done...

[Watto]

nice white hitops mate ;)

[MDM]

:-) we all wore white basketball boots in them days Watto!
So yours was a later model Si, with the rear disc. I was always paranoid about the sidepanels, as a mate had his nicked when he was at the TT, so I lock-wired mine...

[evad]

So how long have you had the zed for Dave?
You had to tilt the tank a fair bit, for motor clearance?

Here is a few pics of mine

http://i75.photobucket.com/albums/i308/sloan_dh/z650/179.jpg

http://i75.photobucket.com/albums/i308/sloan_dh/z650/100_1085.jpg


http://i75.photobucket.com/albums/i308/sloan_dh/z650/08bikeweek004.jpg

[MDM]

Yes evad, had it a fair while now... bout 20 years! And yep, the standard tank sat on the cam cover of the 1100 engine, so I had to raise the rear for clearance. It looked pants, so I've now got a one-off alloy tank that is the same shape as the original, but has cutouts to clear the cam cover and has the fuel tap on the right-hand side instead of the left. Yours is lovely, you thought about changing the rear light for something more svelte? I'm gonna use an SV650 tail light, as it'll tuck under the tail unit really neatly.

[evad]

The alloy tank looks great, classy work.
I have never thought of changing the taillight but will keep an eye on how yours looks once done.
Have you had to brace the frame at all to cope with the extra power?
Yours is a 77 B1 model? Mine is 78 b2 but bought it in April 79 in Cape town South Africa.
It needs refinishing but I am not doing anything until I have finished one of the other projects so I dont sit with out a ride;), funnily enough the other project is a gpz900

[Gix11]

nice white hitops mate ;)

As Dave said mate; standard issue back then. Hi-Tecs of course.

[Gix11]

:-) we all wore white basketball boots in them days Watto!
So yours was a later model Si, with the rear disc. I was always paranoid about the sidepanels, as a mate had his nicked when he was at the TT, so I lock-wired mine...
My memory, much like my brain in general, is very hazy, but I rermber it being a C model. 1978 springs to mind. Correct me if I'm wrong, as the only time I saw the details was on the tax disk (when I first got the bike - ahem...)

Yea, the side panels, just like the tank badges, were gold dust even then. Wire those bad boys on man.

I used to work for Cheltenham Kawasaki in the spares department and there was a store room dating back to the early 70's. One day, while bored, I wandered into the cob-webbed, shit ridden back area and found a little box. Inside it was a brand new Z1 tank badge, still in the original box and paper. It was lovely, ....and I'm loking at it right now next to my computer 22 years later.

oh, and by the way, Evad's (Dave's) fuel injected Z650 is a work of art mate. Subtle but perfect. You'd love it.

[MDM]

When the Dymags were first fitted, I got some bloke to make up the wheel spacers (errr, I think it could've been Big 4 Motorcycles up in the Derbyshire Peaks),along with the caliper hangers for the Yamaha blue spot 4-piston calipers, and a rear caliper hanger for another blue spot. But, at some p[oint, I decided that I didn't want a big 4-potter on the rear, so threw away / lost the spacers and hanger. So, I needed new ones.
So the rear wheel needed centralising and measuring up for some spacers...
Hmm, looks a bit close to the swinging arm on the left.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0072.jpg

The shock mounts and centre casting mark on the Dymag gave convenient reference points.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0074.jpg

Stacks of room on the right hand side, and I'll get a mate to machine up a spacer before I start thinking of a caliper hanger (mainly because I don't know what caliper I'm going to use yet)
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0073.jpg

So it was all measured up with the wheel in place and a couple of spacers ordered. When they arrive I'll be able to bolt it together solid, and check for chain alignment...

[MDM]

You may not be able to tell from the pic, but once it was centralised there was a bit more room between the sprocket carrier and the swinging arm...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMG_0071.jpg

[FIGHTERMC]

could always get some meat taken off it dave.
not a big deal anyway mate.

[Tony Nitrous]

I was always paranoid about the sidepanels

Mate parked his up the side of a bike shop,
went inside, the mechanic went out the back door and stole
his side panels (we found out later)

Same lad died in an accident, his helmet and gloves were left
after the funeral at the roadside with with flowers,
1st night someone stole the gloves !

F#ckin' Kidderminster !!

[Jinx]

Bewdley and Stourport weren't any better either Tony. Scumbags would steal anything that wasn't nailed down. Must be something in the water. Glad I got the fuck out of there when I did.

[Tony Nitrous]

Bewdley and Stourport weren't any better either Tony.

I didnt mind Bewdley, but Stourport I was happy to avoid !
Too many Pikeys, Gypsy Camp sites and council estates.

Shame its so close to Witley Court and the excellent Shelsley Walsh.

Only thing I miss about Stourport was Alec Dorrell,
always looked after me for MOT's. Good old bloke.

[MDM]

Have you had to brace the frame at all to cope with the extra power?


Yup, braced at the headstock, above the swinging arm pivot, between the rear frame rails and where the rear frame rails meet the seat rails. I'll get some pics when (if) I remember.

[Blackkat]

I never owned a z650 but had the use of a mates for a few months, loved it great bike.
And yep so asshole stole the side covers.

[evad]

Cool, thanks Dave. You probably know but if not you can buy aftermarket new side covers now. The 650s are becoming quite sought after, which sucks cause parts used to be cheap unlike the 900/1000s

http://www.z1enterprises.com/ItemDetails.aspx?itemDescription=Side+Cover+KZ650B %2fC+Plastic+Left&item=LP01-1034

[Gix11]

It blows me away what you can get now. Supercharger's Z parts have me craving one again.

[ozzy1100]

come back to the fold si

[evad]

Lol, I told Mark that he would like Z1 Enterprises. Yeah its amazing what you can get for the old zeds. Mark is making great progress with his build, its looking awesome!!

[Gix11]

You're not wrong Dave, his photos are rubbing it in even more. So nice.

[MDM]

Now, I'm not making any promises, but the Zed has been pulled out from under the covers in the corner of the shed and is up on the bike ramp...

[ozzy1100]

Progress is progress lol

[Tony Nitrous]

Was talking about Zeds to a mate at work.
I wouldn't mind another, maybe Z650 or Zephyr 750,
just the frame and bodywork, the rest of it would have to be Suzuki of course.

[ozzy1100]

tony i could do you a z motor you would never forget

[Tony Nitrous]

tony i could do you a z motor you would never forget

Yeah, I've had a Harley i'll "never forget" too !
Had Z1000/Zephyr/ZZR11 and a few others,
Love the Zeds looks but prefer the Suzuki mechanics.

[ozzy1100]

Yeah, I've had a Harley i'll "never forget" too !
Had Z1000/Zephyr/ZZR11 and a few others,
Love the Zeds looks but prefer the Suzuki mechanics.

you do really need to pop around one day again tony i have some great things to run past you

[MDM]

http://i1078.photobucket.com/albums/w481/MDMSF/Facebook/Mobile%20Uploads/1904269_660356544022691_1727676268_n.jpg[/URL]

[hutch]

nice

[Large]

That bitch is shapely and pretty!

[K6Thou]

Mmmmmmmmmm....

[Tony Nitrous]

Very nice Dave. I like it.

[Spanks]

me likey Dave

[Surt]

cool bike mate, would love to see more detailed pics of the tank and frame braced. i work on a kz750 shafty, turning the bloody chopper-like bugger into a cafe racer no turbo this time lol. i have a similar frame (not braced and prolley i won't), side covers (don't want them at all, as well as its stock tank and the whole arse) ahh heres a pic of how it looked when was bought last summer for $300 (other parts are present just put aside

http://i1175.photobucket.com/albums/r638/Surt_Rafrrirr/the%20nightrider/DSCF0042.jpg (http://s1175.photobucket.com/user/Surt_Rafrrirr/media/the%20nightrider/DSCF0042.jpg.html)

sure you know of kzrider.com, just in case

[MDM]

i have a similar frame (not braced and prolley i won't)...



I'll get some pics of the frame bracing and, trust me, it is definitely worth doing!

[Surt]

well i've seen a lot of braced frames on kz rider, mostly of kz900s and 1000s their back bone tubes go 'round down tubes and welded to the neck therefore do need bracing, bur our kz750 frame's designed better. still i love the frame work so would love to see your pics mate

http://kzrider.com/media/kunena/attachments/22439/080_2013-06-30.JPG

[MDM]

Hmmm, so back into the shed and start off with sorting out the rear wheel spacing that I was wittering about months ago. Ah. Just one problem. The spacers that I had made appear to have hidden themselves away somewhere. No matter, I'll get on with something else and hopefully they will turn up. Working on the principle that as soon as you give up on looking for something it appears, usually under your knee when you kneel down, or in the bottom of a shoe, or in the fridge...

[MDM]

So, while trying to find the wheel spacers, I managed to find a shitload of rear caliper hangers, and one caliper. Somewhat unsurprisingly, the caliper doesn't fit any of the hangers, and the chances are that none of the hangers will be suitable for the Zed, but there's something to play with for a bit, anyway...


http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0023.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0023.jpg.html)

[MDM]

would love to see more detailed pics of the tank and frame braced.


Here you go Surt...
Just above the swinging arm pivot point is a brace on each side - deffo the most important bit of bracing if you're staying twin shock.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0029.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0029.jpg.html)

http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0031.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0031.jpg.html)

This one was added after the frame rail was scalloped to give room for the Rajay...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0030.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0030.jpg.html)

And this one shows how the rear engine mount is braced. Also shows the low profile engine breather that I made too.

[MDM]

Oh, last one didn't appear, try again...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0032.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0032.jpg.html)

[Surt]

thanks mate. i cant get whats in the last one? i'll put a part of my pics collection on kzs bracing in my newly opened thead, not to high jack yours, welcome!

[MDM]

The last one is the bespoke rear engine mount - a one-piece affair that ties in left and right rear engine mounts.

[Surt]

alles klar, gotta check whats up with my engines mounts, and my frame is somewhat different from any frame i saw

[MDM]

While waiting for the rear wheel spacers to show themselves I cleared out some crap, and decided to use an SV650 headlight instead of the original Zed one, as it's 246g lighter! Approximately.
Made up some brackets to suit, with an angle of dangle that matches that of the control levers...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0036.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0036.jpg.html)

[Gix11]

That works well mate! This has got to be a record run (working on the bike that is) hasn't it?

[MDM]

Yes Si, definitely! Well, for the last fifteen years and this bike, yes.
And it might be delayed a bit over the next couple of weeks, as just picked up an SV650 for a runabout bike, that needs a bit of work to get it sorted...

[MDM]

Rooting through more bits and found these, which I'll be needing...


http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0024.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0024.jpg.html)


Mikuni HSR42 and float bowl extension kit.

[Iceman]

Nice score Dave, I never find anything that good in my pile of bits....

[MDM]

HSR and extension together as one...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0028.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0028.jpg.html)
Which is all well and good while I waited for the carb adaptor to arrive from Allens Performance.
But when it did...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0034.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0034.jpg.html)
Bugger!

[hyofighter]

you obviously bought the wheelie version , gonna be hard to tune with the wheel up and one hand on the bars but its do able

[MDM]

That pics probably doesn't show it very well, but the carb wants to sit where the frame rail is...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed - the longest project/IMAG0033.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed - the longest project/IMAG0033.jpg.html)
There's no way that the frame can be trimmed, as it'd take all of the frame tube out, and moving it directly outboard would mean a spacer about four inches long and the carb ending up where my right knee wants to be, so it'll have to be an angled spacer that points the carb forward I reckon...

[Surt]

can you make a pic of your intake setup from behind mate?

[MDM]

Yeah, I'll have a go, will probably take the battery box etc out so I can get a pic that shows it properly...

[ozzy1100]

Mechanical injection ? Silly I know but I'm so over efi ATM lol
How would it look or work angling the carb forward ?
Would prob mean modifying the carb and or the the turbo inlet and looking
like a steaming dog turd :-(

[ozzy1100]

I have been looking at getting my grubby paws
on a mates druin supercharger kit mmmnnnn

[MDM]

So, having finally got back into the Shed of Dread, and ignoring the carb issue hoping it'll go away, I started actually doing some stuff. Although, unsurprisingly, not much...
After taking off the temporarily bolted on headers, I took out the two remaining exhaust port studs, and fitted a new set. Ooh, a teeny tiny step forward! I also got a mate to spin up a set of spacers for the oil cooler that I'll be fitting, so I can get on and make the bracketry for that. But had to go back and check out that rear wheel spacing. With the spacers that my good mate Sam had made, I got the wheel centralised within a mill' or so. Which was fine, but as the pic below shows, it is scarily close to the left hand side of the swinging arm, and the chain run is going to be close to the left-hand shock too. Added to which, it's looking highly likely that the chain and rear frame down tube will want to be occupying the same space.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02451.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02451.jpg.html)
I'm now thinking of shifting it to the right by five or ten mm, and accept a slight misalignment of wheels...

[ozzy1100]

It would shit me to have to do so and I have seen runs with
only a few mm of clearance but to honest vmax's and the like
are that far out from std (5mm from mem).

[Redmohawk]

Mushroom head Bolt with nut on outside (aka Disk brake mounting bolt) will give you heaps of room on sprocket side. Down tube might be a little trickeyer though. Cut and Plate ?

[MDM]

Mohawk, that pic is a bit deceptive, it's not an issue with the shock mounting bolt, plenty of clearance there. But you're right with the frame I reckon...

Okay, so while fiddling with my rear end (er...) I found a caliper hanger that matched the spindle diameter, but which needs some machining to make it the right thickness for what I'd discovered on the left hand side of the swinging arm. And I bolted on an SV650 caliper I hand hanging about.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG0250_BURST0011.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG0250_BURST0011.jpg.html)
I dunno if you can see here, but it's right for the offset of the disc (zero) but not for the 210mm diameter.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02531.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02531.jpg.html)
So, with some guesswork and a ruler waved in it's general direction, I reckon I need a disc of 230mm diameter. Either that, or get a new caliper hanger made, and I think that the disc is the easier option! So, anyone know of any online disc dimension lsitings? Some quick measurements show that the disc fitted to the Dymag is a six bolt fixing (so a three bolt one would also do the trick) of PCD 109mm, with the central hole being 99mm diameter.

[MDM]

Oh, and I was reminded about something that's been bugging me since I first built the bike with the 1100 motor - the shock alignment.
When the swinging arm was made by Martek, the shock mounts were wider apart than the standard mounts, so they're a bit 'splay-legged'...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02541.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02541.jpg.html)
So I'm thinking of doing something with the top shock mounts to bring it all into alignment. The shocks worked fine, but it was always something that bugged me, and ikt just wasn't right.
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02591.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02591.jpg.html)

[Surt]

some bikes shocks have an off set upper eye or you can fab/order a custom one mate

[MDM]

Yeah Surt, and while they were fine when I was running the bike before, it just don't seem right. And the thread is a bit ropey on one of the shock mounts too, so it's a good excuse to rectify that, but not 100% certain that I'll do anything yet...

Back with the brake, I'd initially thought that I'd use this hanger -
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02671.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02671.jpg.html)
But as it has a rubber damper in it (dunno why, most don't seem to have it, I think this was from a ZXR750H1) it'd be a bit pants to machine, so maybe I'll go with this one instead -
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02681.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02681.jpg.html)
I've marked it up with the changes that it'd need to work, although I'd still need to find a larger disc, as you can see here -
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02691.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02691.jpg.html)

[MDM]

Old goldfish brain here got distracted again, while I was fannying around fitting the new exhaust studs into the head I had a look inside the headers... and noticed that the inside of the header pipes had some 'clag' (for want of a better word) inside. The headers weren't genuine Mr Turbo ones, as they didn't fit due to the fact that the GPz engine sits further back in the Z650 frame than it did in the 1100 frame, so I had Mickey Burke at Eyeball Engineering in Tamworth make me some new headers (and up-pipe) to suit...
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02641.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02641.jpg.html)
http://i1078.photobucket.com/albums/w481/MDMSF/Zed%20-%20the%20longest%20project/IMAG02631.jpg (http://s1078.photobucket.com/user/MDMSF/media/Zed%20-%20the%20longest%20project/IMAG02631.jpg.html)
Time to get the Dremel out...

[Gix11]

Fun fiddly work.

A lot of action in the shed of dread mate! ...on a roll?