Z1R BUILD

[John H]

I should of cleaned both gauges since both appeared to have been assembled without a clean lense.
Thanks for sorting, testing and modifying the wiring harness. It's installed now and everything works great. Ignition spark is weak and more comments from KZ forums suggest the coils were marginal at best even when new. I'll order the new coils from Z1 Enterprises as you suggested. The Gerex Multifire will be a backup system if needed.

A little bit of pre-assembly.

pre assembly.JPG (302.06 KiB) Viewed 4561 times

[Lotus54]

Latest status?

[John H]

The Z1R got sidetracked when I brought the Desert Racer home. The idea was to just do a mechanical update but the more I got into it the more I found that needed more than just a cleaning and checking. Now it's down to the frame and motor and no end in sight. At some point I will get back on the Z1R. It just a few small things to finish it up, like tires, brakes and fuel tank clean out.

[Lotus54]

Yeah, just a quick clean up… hahahaha

[John H]

I had a heck of a time getting the old Michelin tire off the rim then spent some time cleaning, polishing and coating the polished areas with ShineSEAL which should keep them looking nice.

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Spent some time rebuilding the forks just to be on the 'clean' side of things. When it came time to install the front wheel, it wouldn't go. I thought 'here we go again, bent triple trees or bent forks. I removed the lower tubes and measured between the upper tubes at the tree and again at the bottom and the difference was less than .007". I loosened each fork tube and rotated them until the difference was .003". I reassembled the forks but the wheel was still .080" too wide to fit correctly. No help after doing a bit of research so I removed .080" off the spacer and it's finished.

Front wh.JPG (283.32 KiB) Viewed 932 times

I finally installed the fairing thought I was finished with the front end only to find the headlight doesn't light up. Here we go...again.

[John H]

Well that wasn't so bad. With the fairing off again I found a loose connection. I'm amazed it all works as well as it does.

Wire in fairing.jpg (289.1 KiB) Viewed 788 times

I decided while the fairing is still off it's a good time to bleed the brakes as the reservoir is tucked in there.
Hope there are no surprises there.

[John H]

The brake bleeding didn't go so well. After a couple of attempts I started again checking the master cylinder for blockage. This master cylinder was a one year only for the Z1Rs and corrosion has destroyed most of them. I bored and sleeved it back to size but couldn't find a rebuild kit so used the cups from a kit that was similar. As it turns out I drilled the larger hole from the reservoir to the piston but failed to drill the .020" hole in front of the pressure cup. That did the trick and the brakes now work great.

Front Master cyl..jpg (290.63 KiB) Viewed 659 times

[Lotus54]

Glad you found the loose connector. Especially older bikes connectors are usually first thing I inspect. But with all of those…

Curious if you bored the master with mill or lathe. Seems could be easier to hold in the mill?

[John H]

Both master cylinders were bored in the mill. The sleeve was a snug fit as I didn't want brake fluid going around it causing a leak.