Z1900 back from the grave.

[Supercharger_Mark]

Bought this off Ebay a few months back, it T boned a car turning right while overtaking,and sat in a shed for 27 years.
4725

Just about everything was fucked, accept the back wheel. engine had two snapped valves, I found a gear tooth in the sump, frame was fucked forks fucked frontwheel fucked, taco speedo seat tank side covers tail peace blinkers fucked fucked fucked.
472647274729

The frame was too stuffed to straighten so I decided to chop all the bent bits off.
4728
Fuck! not much left, should I rebuild or buy another frame?
Well I'd never built a frame before and this one was nearly half done, so I bought some chrome moly, made a pipe bender from scrap I had around the house, studied up on frame geometry and got started.
Used a sheet of 12mm thick steel for a base, made up a few jigs (sorry, forgot to take pics) my lathe was too small so I got the local engineering shop to turn up the head stock then started bending cutting and welding,
4730


47314732
So far so good. everything lines up spot on.

[ozzy1100]

Mmmnnnnnn now this is my style top job mark

[Gix11]

Come on Supercharger, don't be shy. Keep the photos coming!

[ozzy1100]

What he said ^^^^

[Hagarr]

Now that's a rebuild!

[Iceman]

Top job Mark.

[evad]

Looks Great Mark, I'm with Si..... where are the other pics :-)

[Supercharger_Mark]

Did a bit more to the frame, tank mount, coils mount, rear foot pegs mounts and gusset under the steering head.
47344735473647374738
Just need to weld the steering stop to the head then off to get sand blasted and power coated.

[evad]

Im amazed that you have been able to resurret that frame!!! Amazing work Mark.

[Large]

That's pretty impressive work Mark.

[Supercharger_Mark]

Thanks for the comments guys, but the proof's in the pudding, I'll be happy if it doesn't spit me off in a big tank slapper.
Here's a few more pics of what else is going on the bike.
Shimmed the new disks to line up with the callipers, the rim is off a SV650 and the forks are ZZR1200 so a fair bit of spacing to do there, the speedo drive is off a 86 gsxr1100.

474447454746

The same deal with the swing arm with shimming, which is off an 01 GXSR600, the back wheel is Bandit 1200 as is the calliper hanger and drag link.

47474748

474947504751

[ozzy1100]

stop it mark I will need to clean up soon........real bike building imo
what probs with rego do you think you will have
and what filler wire did you use for the 4130 ?
Really good use of lesser used better value later model factory parts, while still keeping the clasicc vibe I love it.......

[geesexar]

love it Mark..good job and long live the Z

[Supercharger_Mark]

Ozzy,I bought the cromoly off RaceTec and used the rods theyrecommended, it has ER 70S-2 stamped on the ends.
And no more questions about rego, I don't want to dampen my enthusiasm.

[Large]

Supersteel!

[ozzy1100]

Ozzy,I bought the cromoly off RaceTec and used the rods theyrecommended, it has ER 70S-2 stamped on the ends.
And no more questions about rego, I don't want to dampen my enthusiasm.

that pain I feel only to well my brother......
er 70s-2 is the spec that keeps comeing up with the people in the know that I have spoken to
racetec is where i was thinking of useing but there is a few other places its stocked well
I just shouted myself a jd2 square bender model 32 for this propose, paid for it with scrap money and designing a paying job that uses 3/4 s/s tube bent- by luck should have it the stars alined and with just my time and some small cash the $1500 paid for its self.
what did you use to bend it, it can take no small amount of force :-)

[ALBI]

is it me but in the second pic of finished frame front on the headstock looks to be of ??

[Supercharger_Mark]

(jd2 square bender model 32) Yeh, I wish I had one of them, I made up a very basic bender and yes it was very hard to bend, so hard in fact, reluctantly, I needed to heat it and then let it cool slowly.
Albi, Yeh, but on the jig it lined up well, hard to tell from a photo.

[Supercharger_Mark]

Got some new bits ready to go.
47574761476047584759

[ozzy1100]

im just starting in this but by the look of it the section you prob had to heat is trianglelated by the stright bar anyway, at the end of the day 4130 has got to be over x2 the strengh of the mild it replaced so while its not what Id do there is never really much chance that its going to be a problem. I have plans afoot to build the frame jig to end all jigs, problem is that its going to cost upwards of 1k and take me 3 mths to build it and thats if the place sells me their old milling machine bed they have........
thats not a easy task you took on there and if it was me id be chuffed with the result


as you can tell I kind of love that paint
http://i1136.photobucket.com/albums/n493/ozzy1100/DSCF3107600x452.jpg (http://s1136.photobucket.com/user/ozzy1100/media/DSCF3107600x452.jpg.html)

[Supercharger_Mark]

I've owned lotz of bikes but the Z1 I had when I was 19 was the bike I wished I kept.4762
This one I'm building was a Z1A, but I'm making that many changes I may as well have the paint job I like.
I guess I'm trying to replace the Z1 I had, I hope it lives up to my expectations.

[slingy88]

Cracking build mark well done ;)

Are you going to monoshock the frame to suit the GSXR arm or convert the arm to twin shock to suit the frame?
I think i know the answer to this but curious to see which way your going to take it lol

[ozzy1100]

I've owned lotz of bikes but the Z1 I had when I was 19 was the bike I wished I kept.4762
This one I'm building was a Z1A, but I'm making that many changes I may as well have the paint job I like.
I guess I'm trying to replace the Z1 I had, I hope it lives up to my expectations.

Grean is hard to get out the blood mark lol
Don't feel bad, makeing it better than it was out of pieces
no one else would touch and keeping the spirt alive....
Sounds like win win

[Supercharger_Mark]

I'm going to convert the arm to twin shocks Slingy, I'd like to keep the original look as much as possible.
I bought these which are 1mm shorter than the original shocks, they were to fit a gsx1400.
4766

I'd like Olins but I've already spent a fortune so these will have to do for now.

[TurboKat]

Turbocharger Mark?

http://www.ebay.com/itm/kawasaki-1973-74-75-76-77-78-kz-900-1000-z1-mr-turbo-kit-s-s-super-e-carb-/281157576952?pt=Motorcycles_Parts_Accessories&hash=item41764c28f8&vxp=mtr (http://www.ebay.com/itm/kawasaki-1973-74-75-76-77-78-kz-900-1000-z1-mr-turbo-kit-s-s-super-e-carb-/281157576952?pt=Motorcycles_Parts_Accessories&hash=item41764c28f8&vxp=mtr)

[ozzy1100]

Turbocharger Mark?

http://www.ebay.com/itm/kawasaki-1973-74-75-76-77-78-kz-900-1000-z1-mr-turbo-kit-s-s-super-e-carb-/281157576952?pt=Motorcycles_Parts_Accessories&hash=item41764c28f8&vxp=mtr (http://www.ebay.com/itm/kawasaki-1973-74-75-76-77-78-kz-900-1000-z1-mr-turbo-kit-s-s-super-e-carb-/281157576952?pt=Motorcycles_Parts_Accessories&hash=item41764c28f8&vxp=mtr)

what would you blokes pay for a reproduction drouin supercharger kit

[Supercharger_Mark]

That's just cheating.

[slingy88]

I'm going to convert the arm to twin shocks Slingy, I'd like to keep the original look as much as possible.
I bought these which are 1mm shorter than the original shocks, they were to fit a gsx1400.
4766

I'd like Olins but I've already spent a fortune so these will have to do for now.

Yep, thats what i figured would be the prefered option. Its good though, leaves a nice vacant hole in the swingarm to bring the exhaust up through to a stealth underseat blowthrough turbo instead of some 40 yr old design draw through MRS Turbo thing ;)

[ozzy1100]

Yep, thats what i figured would be the prefered option. Its good though, leaves a nice vacant hole in the swingarm to bring the exhaust up through to a stealth underseat blowthrough turbo instead of some 40 yr old design draw through MRS Turbo thing ;)

afr10 had just that

[evad]

You mean this one?

http://www.streetfighters.com.au/forum/showthread.php?285-jaffaZd-s-z900-Turbo

[ozzy1100]

You mean this one?

http://www.streetfighters.com.au/forum/showthread.php?285-jaffaZd-s-z900-Turbo
thats the one dave ...horn as was his mates one the gpz with a zx12r motor in it

[evad]

yeah that was Pizz his brother in law I think. Had me going with running a autronic ecu and carbs :-)

[slingy88]

You mean this one?

http://www.streetfighters.com.au/forum/showthread.php?285-jaffaZd-s-z900-Turbo

yeah, i was thinking of that bike actually Dave. I could look at that for hours.................(sucks drool back into mouth). Oh well back to looking at my crusty Gixxer i suppose, now wheres me soldering iron...

[Supercharger_Mark]

A few more pics of what's going on the bike.
Wiseco 1015 pistons4768
4769477247714770

Dina s electronic ignition, Bandit coils, Slabie 34mm carbs & headers.
Maybe I should call this a Kawazuki build.

4767477847744773

And some more random pics.
477747754776

A quick fit to make sure the main bits go together ok.
47804779
My 2nd home.

[ozzy1100]

Love the work space :-)
Those pipes look horn, good honest build should run awesome
Apart from my dislike of wiseco lol

[Gix11]

How'd you go with those crappy pods mate?

[Supercharger_Mark]

Si, they made up new dies for the foam base just as he said they would, I thought he was taking the piss.
The new filters arrived last week, these ones fit fine.4784

I can't afford the top triple clamp I'd like so I decided to make an adaptor that fits on top of the original clamp, its still a work in progress, here's a couple of pics, not sure if I like it yet.


Chopped off the key holder4787
Cut up a peace of aluminium to shape4788


Lathed a recess to fit the clamp 47894790

Did some more cutting and hand filing, I still have to 479247914793
make spaces and bolt the rises on.
I put the frame in yesterday to get sand blasted and powder coated
And that's as far as I've got so far.

[Supercharger_Mark]

Got the frame back, looks great!480448034805

Put the wheels on and the motor in.48064807

Made a couple of side plates to sandwich it all together.4808

Made up a few more spaces and linkages for the pegs, gear changer and Mounted the rear brake master cyl,

48094810

I needed to make another gear changer leaver because the angles were all wrong on the one I brought.


481148124813481448184815
4817

[pav69]

i could save you the trouble of making all these bits by taking the bike as is ,because i cant afford one because they are too bloody expensive now thanks to some dipshit paying to much in the first place ,by the way mark bike is coming along quite bloody nice

[evad]

Wow, great progress Mark.... Looks tuff!!

[Mr Hyosung]

So who's a happy boy then?48424843

[Gix11]

I would be too...

[wackyrider]

Wow, looking good Mark

[Supercharger_Mark]

Painted and finished off the side plates and linkages.


4846 4847

Then started on the electrics, fitted the battery box etc.


4848

Rewrapped most of the main harness and zip tied it in only to discover the tail light and dash lights wont come on, FUCK!! after a fair bit of electrical circuit study and head scratching I did some exploratory surgery on the harness and found the break, Thank fuck for that, electrics aren't one of my strong points.

4849

Re soldered the break and put it all back again, all good.

48504851

Got the new tyres on the rims.

48524853

But not there yet, thinking of putting a Buel 1125CR mudguard on or making my own, give me your opinions please.

4854

[Gix11]

That front guard looks good mate, you should try that.

[TurboKat]

Shorty chromed steel guard, it'd fit the 'original but custom' feel of the rest of the bike I reckon.

[hutch]

looking good mate

[Supercharger_Mark]

A few more progress pics.
48604861486248634864


Although the headlight and instruments are in the correct position they look too high to me and I was thinking of dropping them about 2 to 3 inches, waddayarecken?

[Redmohawk]

I'd wait till you got the bars on , will prob change the percevied hight. But I think they might look nicer a little lower just the same

[Supercharger_Mark]

Yeah I think your right, I've been looking at a few pics of Z1's other people have done and lower looks better I think.

Sumthin like this.

4865

[Supercharger_Mark]

Getting close now, Still waiting for the flat bars, bar ends, hand grips, switch gear, grab rail, rear blinkers, clutch cable and a few other bits which should arrive next week.
I decided to go with the Buell guard, I also dropped the headlight about Two inches, I think it looks ok.

490349044905

The chain was a squeeze, about two mill each side.

4906

[Gix11]

Getting close mate. I'll have to get over there soon hey?

[Supercharger_Mark]

Yeh, I think its about time for another Barby then ride. You got your balance back yet Si?

[geesexar]

mark she is lookin spick

[ozzy1100]

I'm liking the front guard mark

[hyofighter]

this bike is awesome , my dream build , top work

[Large]

You dun good Mark.

[Gix11]

Yeh, I think its about time for another Barby then ride. You got your balance back yet Si?

Yep. Still haven't sorted that chain and sprocket set though. Good hey?

[Supercharger_Mark]

Thanks for the comments everyone. I got a few more things in the mail today and sorted out the exhaust as well.

4909491049114912

Stole the muffler from the 1100 till something else comes along, and decided to use the old Marzocchis which still need a good clean up.

[Gix11]

Man I'm looking forward to seeing this!

[wackyrider]

Nicely done Mark.

[Supercharger_Mark]

All I need now is a 25mm drop triple clamp from Ben and a centre stand an its finished.
5279

[K6Thou]

Very nice. Just don't let Lynton near it, he'll spoil the paint......

[Bob]

Looks great mate. Very nice

[MattyDucati]

Mate thats just Sweeeet looking, hows she ride?

[ozzy1100]

leave it with me and Ill give it a power up :-)
love the bike but still not a fan of the seat
really did turn out nice tho

[hyofighter]

that looks awesome superchargermark well done , not to knock your work but I reckon the lower parts of the fork would look good in black to match the swinger

[Large]

That's fucking nice.

[El_Hefty]

yep

[Supercharger_Mark]

Thanks everyone for the nice comments, I'm still sorting the ride, so far no wobbles at any speed, corners great on a good road but the suspension is still too hard and it jumps and bucks on the ruff roads (you know the ones) I've move the rear shock mounts forward which made a big improvement and changed the front fork oil to 5 weight which was a bit better but not good, so I'm now studying racetech suspension bible... (thanks Tim) to try and educate myself.
I like the look of the seat but its about 20mm thick for the rider and is as hard as fuck, not good.
And I agree Hyofighter that the fork legs need to be black, when I get the triple clamp made I'm sending it as well as the swinger, centre stand and a few other bits and peace's to the powder coater to paint in Saturn black.

[BANDITROD]

Wow that's sexy mate

[Mr Hyosung]

Mark thought carbies were a bit boring

5800580158025803

He's now starting to think they are not such a bad thing

[davo]

I see the problem here...Huddo is doing the wiring..and probly using an ECU map of Tasmania. Stick with it Mark. EFI is not that hard compared to jetting once you get ya head around it.

[Large]

What throttle bodies and ecu are you using Mark?
Cam sensor?
Crank sensor?

[Gix11]

I bet the phrase "Got me fucked" has been used a lot of times. Mark likes that line.

[Supercharger_Mark]

Yes Si, that was pretty much the case at that time, its been a steep learning curve but I think I have it sorted thanks to Slingy and Evad.
I'm off for another test ride tomorrow, and if all goes well, some mapping.
Large, the ECU is a MicroSquart3 with TunerStudio to tune it, the throttle bodies are off a GPZ 750 turbo they are only 30mm, the ports are about 29mm. I decided to do fuel only till I get my head around the injection part, I have a 36 missing tooth trigger wheel and a pickup from a early gsxr on order, no cam sensor. and Davo I did try the ECU map of Tasmania but it felt a bit wet and soggy.

[evad]

So Mark, how is this going now? Did you get all your issues sorted out?

[Gix11]

It's got ZXR forks on it now, but I think the fuelling still has him fucked....

[Mr Hyosung]

Ever since Mark got it going, he has always said that it wasn't going right. We told him it was good and that his memories from 40 years ago were a bit dim. He gave it a compression test the other day and found one cylinder only had 75psi. He was right, it wasn't going right. A lot of air is getting past one piston, rings and piston look good, so the barrels are off to the engineers to get measured

[Gix11]

Yea, that's right. I remember now! Fuck I'm useless; I blame those cookies.

[ozzy1100]

Did someone mention cookies....

[evad]

Lol, hope you are sharing those cookies Si 
I must try and get hold of him i n the not 2 distant future

[Mr Hyosung]

For those of you who were wondering how the Z1 was progressing
7408
I think his dreams have all come true

[ozzy1100]

That is just plain wrong lol

[Gix11]

Just needs a taller sissy bar. Best Z1 I've seen by far.

The bike is fitting of his performance on Saturday night actually.....

[Mr Hyosung]

What's wrong with that Ozzy? Not the right colour? or that he doesn't have his riding thongs on.

[ozzy1100]

It uses water....plan and simple, I try only to use water to boil for cups of tea.... :-)

[Mr Hyosung]

And to fill the bong

[ozzy1100]

Sorry mate I roll.... ;-)

[Supercharger_Mark]

Terry that's just not fair, your ruining my reputation, and Si, were you the one who spiked my drink?

[Gix11]

I like the way you say "Drink" singular. I'm sure I saw you do a lot more than a singular drink.

I was told that you were on some kind of health kick and decided coke was bad for you so you went neat rum instead. How did that work out? Feeling healthier? You definitely weren't looking healthier....

[Supercharger_Mark]

No comment.