Big Zed Build Thread......

[KTMboy]

Right, with all this spare time on my hands I thought I’d crack on with my big zed build and see if I can muster the patience to do a build thread as I progress....

The plan is turn this badly modified 1980 KZ1000G



In to something like this.....

[KTMboy]

This is the plan:

1. De-tab and powder coat frame - done by previous owner
2. Strip the top end and fit new pistons & rings, cam chain tensioners etc
3. Rebuild the head
4. Media blast the engine and enamel the whole thing satin black with perhaps a couple of silver casings
5. Mikuni RS34s and Kerker 4 into 1
6. ZR1000 Showa BP forks and triple clamps, bottom yoke with custom machined stem to fit in KZ Headstock
7. ZR1000 front wheel, radial callipers and braided hoses
7. Massive JMC braced swinging arm and decent shocks
8. ZR1000 rear wheel and rear brake
10. ZR1000 handlebars and controls
11. Digital Dashboard
12. Total rewire using M-Unit, LED lights and indicators
13. New seat
14. Genuine Z900 tail piece and side panels
15. Fancy pants paint job
16. Lots of stainless fasteners.....

[KTMboy]

Yeah, won’t be doing any of that... I’m not planning on racing it....🏍

Already got the JMC.....fantastic piece of 80s go-fastery and completely over the top...

[KTMboy]

I’ve faffed about since last summer working out what i would do with this bike. Originally I’d planned just to lightly restore it, but then it became clear just how badly bodged it had been over the years, plus it had low compression on No 3, so I thought a full resto was in order. Then I thought I’d lightly mod it, with bigger forks and 18 inch wheels from the later Police models, so I bought all that stuff and got started. Then I realised that just how boring it is stripping paint off stuff ready to be repainted etc, so I though bugger it, I’m going to go full restomod.

I picked up a few parts and mocked up the rolling chassis....

[KTMboy]

Some of the nice things I found as I stripped it down.....

Firstly the wiring has been butchered and lots of melting going on.... full rewire from scratch will be required.

[KTMboy]

Progress today......stripping the black paint from the engine .... horrible job....



Enamelled the sprocket cover

[KTMboy]

VHT paint stripper

Dremel wire brush

VHT engine primer - 2 coats - no more

VHT engine enamel - 2 coats - no more

Paint oven 100c for 30 mins

[KTMboy]

Got all the paint off the engine, and noticed a few things to attend to before I get busy with the masking tape:

1) Took the oil filter out to change it and there was a lot of oily sludge in the bottom - reckon I’ll have to drop the sump pan and clean the bottom end and oil pump out
2) noticed a few of the seals were weeping on gearbox cover, so I’ve taken the cover off to pop some new seals in..... there was plenty of oily sludge in there too .... hoping I don’t ever have to delve deeper than this .....

[KTMboy]

As suspected plenty of sludge in the bottom of the sump, plenty of lumps of old gasket and silicone but luckily nothing metallic....



15 mins in the parts washer soon cleaned it up..... stripped the oil pump and chucked that in too....



So the plan is to enamel the main engine casing aluminium silver and then all the separate engine casings, the block, head and valve cover a nice black.... with new gaskets all round.....

[KTMboy]

Cool

[KTMboy]

My previous builds.....





[url]

|https://thumbsnap.com/spjHce7A[/url]

[KTMboy]

Thanks everyone...... she was going to be on display at the Bikeshed show 2020 but obviously they’ve cancelled it.....

[KTMboy]

rosetank said:

Megaflow said:

Isn't it just! Lots more pictures of that are required...

Definitely the best of the bunch, paint scheme is great on that one.

Is that an RS125 seat unit?

good spot, a very cut down RSR 250 seat unit actually.....

[KTMboy]

Forgot to show the cockpit, with its beautiful matching Brembo master cylinders. I really like how the Koso dash light colour matches the Öhlins fork tops. It’s keyless go hence the ignition blank.... took a lot of time on the wiring ....

[KTMboy]

rosetank said:

Beautiful. We’re you not tempted to machine the barrel casting off?

There’s a little sensor in there for the keyless fob in case I need to override the bluetooth....

[KTMboy]

Turn7 said:

Bonus points for a choke lever......bet theres some who have never used one before

Bit of old school tech in amongst all the electronics .... that’s off an early Fireblade....

[KTMboy]

jason61c said:

I've a brand new over racing swingarm if you want a proper one for it.

Send me a pic and a price please 😀

[KTMboy]

Right, time to start to putting down some paint.... finally this project starts to get interesting ....

[KTMboy]

gareth_r said:

Megaflow said:

We were supposed to be going this year, are you going to take it next year?

What is it based on Speed 4?

That started life as one of the original 1990s 885cc triples. Trident/Daytona/Trophy/Sprint/Thunderbird/Legend TT/Adventurer/Tiger.

Started off as a 1998 Sprint SE 900 ... like this one.



I’ve actually got an absolutely mint Daytona 900 too.... got a thing for those old triples...

[KTMboy]

Ready for the oven...