Big Zed Build Thread......
Discussion
KTMboy said:
Sorry, I’d actually used a 7mm drill and its perfect, but of course too big for helicoil now - my bad. M8 fine it is then... the M6 location dowels in the carrier have to go though, and no scope to replace with M8 as there is not enough room so be interesting to see if it will all line up afterwards......
I'll admit to scratching my head a little bit there but cool, hope it works out. Take extra care to drill and tap straight. Edit. Sorry to change the subject but have you decided on your ignition system yet? Is yours the later electronic ignition or earlier points? Mine has points but one of my HT leads has been cut and is now too short so I decided to replace the lot with Boyer Bransden's electronic KIT00288 which has arrived but not fitted yet. Just wondering what you were doing with yours?
Edited by mygoldfishbowl on Wednesday 6th May 07:39
mygoldfishbowl said:
I'll admit to scratching my head a little bit there but cool, hope it works out. Take extra care to drill and tap straight.
Edit. Sorry to change the subject but have you decided on your ignition system yet? Is yours the later electronic ignition or earlier points? Mine has points but one of my HT leads has been cut and is now too short so I decided to replace the lot with Boyer Bransden's electronic KIT00288 which has arrived but not fitted yet. Just wondering what you were doing with yours?
Got a nice big pillar drill with a table big enough for the head so hopefully I’ll get those M8 threads exactly where I need them....Edit. Sorry to change the subject but have you decided on your ignition system yet? Is yours the later electronic ignition or earlier points? Mine has points but one of my HT leads has been cut and is now too short so I decided to replace the lot with Boyer Bransden's electronic KIT00288 which has arrived but not fitted yet. Just wondering what you were doing with yours?
Edited by mygoldfishbowl on Wednesday 6th May 07:39
Mine has the later electronic ignition but no idea how it works - I was going to worry about that later. The bike did run before I took it all apart....
Finally got round to working on Big Zed’s head....trying to fix all the knackered threads for the exhaust cam carrier bolts....
Went M8x1, took it nice and slow, removing one locating dowel at a time - drilling and tapping the new hole then drilling the carrier - bolting it all back together to check alignment - and repeating the process - 8 times.....
I also had to turn down the heads of the bolts as is turns out there is so little clearance with the cam cover....
Took a good few hours but I’m all done and the cam runs very smoothly with zero play......
Went M8x1, took it nice and slow, removing one locating dowel at a time - drilling and tapping the new hole then drilling the carrier - bolting it all back together to check alignment - and repeating the process - 8 times.....
I also had to turn down the heads of the bolts as is turns out there is so little clearance with the cam cover....
Took a good few hours but I’m all done and the cam runs very smoothly with zero play......
Moved on to the swing arm, shocks and rear wheel, just measuring up for spacers etc...
JMC swing arm is stamped GPZ1100. Fits nicely in the frame but needed a sleeve for the smaller 16mm swing arm bolt of the old Zed. I had some nice Bitubo shocks from a Thruxton which only needed 14mm sleeves in the bottom eyes.....they are 20mm longer so jack the rear up a little to get some more weight on the front wheel...
Rear wheel now needs spacers measuring up....and then figure out out to secure the rear brake carrier. Hopefully there will be the space to fit a chunky tie rod....
JMC swing arm is stamped GPZ1100. Fits nicely in the frame but needed a sleeve for the smaller 16mm swing arm bolt of the old Zed. I had some nice Bitubo shocks from a Thruxton which only needed 14mm sleeves in the bottom eyes.....they are 20mm longer so jack the rear up a little to get some more weight on the front wheel...
Rear wheel now needs spacers measuring up....and then figure out out to secure the rear brake carrier. Hopefully there will be the space to fit a chunky tie rod....
Cracking build !!! Love the old Zeds, at 18 I had an old GSX250 twin with a 450 lump shoehorn’d in. At the time my dad owned a ‘81 Z1100 shafty and a local old boy told him he had a couple of old Zed’s he wanted shot of. I ended up swapping my GSX for a 1978 Z650 AND a 81 Z1100 shafty... couldn’t leave the guys house quick enough !!!
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