Z1R BUILD

[Lotus54]

If you need anything big vaporhoned, just hollar. I am glad to do it.

[John H]

I appreciate the offer on vapor blasting.
I completely stripped the frame for powder coating, only if they can protect the sticker on the steering head.
I can't believe how much additional electrical components they added on this bike. I have other harnesses from early Z1's but none of them had backup system modules or turn signal cancel solenoid or hazard indicators and so on. I first thought the harness may be for a 1980 since this bike has electronic ignition but the 1978 came with points. I'm still looking for a wiring diagram for help putting it back together.

IMG_0626.jpg (321.23 KiB) Viewed 42742 times

.

IMG_0614.jpg (243.95 KiB) Viewed 42742 times

[John H]

The 2-pak paint and primer arrived so now I have to arrange parts so all can be primed and painted within 24 hours. Some of the small parts will get powder coated depending on when the activated paint runs out. Some of the cad plated parts look decent so to preserve the finish they will get a clear simi-gloss coating of 2-pak. The engine stand adapter will allow me to rotate and paint the crankcases without any handling. Also I can roll it into the warm room to accelerate the drying time if needed.

Eng Stand for paint.JPG (311.49 KiB) Viewed 42448 times

Engine Bolts.JPG (274.2 KiB) Viewed 42448 times

[John H]

Been away for a while but made some progress, including adjusting two new additions. Not shop broke yet but working on that.

New pups.JPG (293.38 KiB) Viewed 41186 times

I've been going over the frame in preparation for powder coating. Upon removing the forks I noticed the steering lock slot in the stem was damaged. More inspection showed that the lock was destroyed and would not come out. It became necessary to remove the lock sleeve from the frame to repair. Once that was finished the slot in the stem was welded and reshaped. Now off to powder coating.

STEERING LOCK4.JPG (209.06 KiB) Viewed 41186 times

STEERING LOCK1.JPG (262.56 KiB) Viewed 41186 times

STEERING LOCK7.JPG (186.41 KiB) Viewed 41186 times

STEERING LOCK8.JPG (132.46 KiB) Viewed 41186 times

[Lotus54]

Can’t wait to see the frame.

[John H]

The frame looks so good I had all the small parts powder coated as well. With a great weather forecast for this weekend I'm hoping to get the motor painted.

Frame1.JPG (284.73 KiB) Viewed 40764 times

The clutch has been rebuilt, including the replacement of the shock springs and rivets. The trick is getting the bellville spacer
compressed before welding the ends of the new rivets. This will eliminate the 'Ducati rattle' sound.

clutch2.JPG (318.87 KiB) Viewed 40764 times

clutch1.JPG (198.76 KiB) Viewed 40764 times

[Lotus54]

Looking darn good!

[John H]

Still waiting for good painting weather and got sidetracked refurbishing the toolpost grinder. The motor shaft nut that holds the belt drive pulleys on was damaged so decided to make a new one. I can only guess now why as it is a left hand thread. To make matters more complicated, it is a 24 pitch thread. No luck finding one available anywhere so spend a few hours making 1/2-24 LH nuts until I was satisfied with one that fit just right.
Been searching for the Z1R upper right motor mount. Gave up, so set the crankcases in place and made a template then the mount.

Screen Shot 2024-03-22 at 10.40.51 PM.jpeg (82.99 KiB) Viewed 40602 times

Motor mount.JPG (177.56 KiB) Viewed 40602 times

[John H]

It was a bear getting the wires out of the handlebars. Going back in was a bit easier by using some wire pulling lube and heat.
All the switches were disassembled and contacts cleaned before reassembly. Hope it all works. All the components and the main harness will be layed out on a large board so everything can be tested. The only variation from original is the electronic ignition vs the points and condenser, and an extra pair of resistors.

Handlebars done.JPG (231.62 KiB) Viewed 40361 times

Dash wires copy.JPG (255.33 KiB) Viewed 40361 times

Inside photo of the dash.

Wiring dash2 copy.JPG (323.37 KiB) Viewed 40361 times

[John H]

Still too cold to paint so prepping the final parts. The original cam covers were painted black with only the outer ends being polished. The cam cover on this bike was chrome plated and it has started pitting. I had thought of using muratic acid to strip it but it would have been difficult so started going through some old metal finishing supplies left from my business in architectural metal fabrications. Between the Nylatron wheels and the 3m scotch wheels I was able to get a finish I think the 2k epoxy will adhere to. Surprisingly the chrome on all 4 outer ends are in good condition and will polish out nicely.

Cam Cover Strip.jpg (301.29 KiB) Viewed 40234 times

. An example of the polished ends.

s-l1600.jpg (97.34 KiB) Viewed 40234 times