Eddie's 1100 Rebuild

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Eddie's 1100 Rebuild

Postby Eddie » 07 Nov 2017, 22:47

I've owned my Zephyr since 1997 and modified it over the years including ZZR wheels different suspension and exhaust etc. Unfortunately in 2013 I had a crash on it which left us both dented and with some broken bits!!. With a job change and loss of storage I stripped it down and put it in the upstairs spare room....apart from the engine which I couldn't lift :) . Fast forward 4 years and I've now built a workshop in the back garden finished a couple of unfinished bikes and bought my dream bike, a 1978 Z1000 :D
Anyway it's time to get the Zephyr done, I'm pretty much going to re build it back to as it was (there's a pic in the showroom thread before I binned it!) but with a few mods and changes here and there. I'll post updates when I can and hopefully progress won't be too slow, but feel free to comment or take the piss!!

DSC_0803.JPG


It's finally on the ramp
DSC_0811.JPG


cheers eddie
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
86 Honda XL600R supermoto
73 Honda XL250 Motosport
79 Yamaha XT500
80 Honda Z50R Monkey
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Eddie
 
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Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Postby Eddie » 07 Nov 2017, 23:08

The engine suffered some damage to the crankcases which needed welding up so I can re attach the left side cover, these were taken a while ago but I'll put them up so you can laugh at my attempts to move the great lump :lol: ....how did they make it so heavy!

008.JPG


DSC_0315.JPG


I took the passenger seat out of my car, a couple of planks on some bricks borrowed from next doors wall and in it went!!!

DSC_0318.JPG


The things we do hey!
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
86 Honda XL600R supermoto
73 Honda XL250 Motosport
79 Yamaha XT500
80 Honda Z50R Monkey
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Eddie
 
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Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Postby Eddie » 07 Nov 2017, 23:31

A local guy to me did the welding and made a lovely job of plugging the holes , I'm sure when I've ground the welds down and painted the engine you'll never know, a big relief as I didn't want to replace the engine as it's such a good one.

DSC_0320.JPG


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Cheers for now eddie
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
86 Honda XL600R supermoto
73 Honda XL250 Motosport
79 Yamaha XT500
80 Honda Z50R Monkey
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Eddie
 
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Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Postby Swampy » 08 Nov 2017, 01:04

Love It, especially the engine in the front of the car (I really thought that you were joking) :o
Keep up the good work Eddie !


Swamps :)
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Re: Eddie's 1100 Rebuild

Postby Eddie » 20 Nov 2017, 23:44

I want to change the rear brake calliper to a under slung type, so I'm going to use a period ZZR one to match the wheels. Will have to cut the torque arm lug off the top of the swingarm and re weld it underneath, job done! Here's a quick mock up:

DSC_0804.JPG


Unfortunately the Zephyr disc is approx 5mm too small , but I have a good ZZR one that is a straight swap.

:D
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
86 Honda XL600R supermoto
73 Honda XL250 Motosport
79 Yamaha XT500
80 Honda Z50R Monkey
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Eddie
 
Posts: 66
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Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Postby Swampy » 21 Nov 2017, 10:32

Looking good Eddie,i didn't realise that you were a pro at this sort of thing :shock:
Good on you :lol:

Swamps :D
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Re: Eddie's 1100 Rebuild

Postby Eddie » 25 Nov 2017, 13:04

Cheers swamps, i'm definitely a pro something as people tell me!!

Quick update, i've dropped off the damaged top yoke at Pretech engineering to have a new one made along with some bar clamps and a nice alloy brake torque arm for the rear, i'll post some pics when i get them back
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
86 Honda XL600R supermoto
73 Honda XL250 Motosport
79 Yamaha XT500
80 Honda Z50R Monkey
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Eddie
 
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Re: Eddie's 1100 Rebuild

Postby HeavenEleven » 04 Dec 2017, 18:33

Good work Eddie.

Looking forward to seeing him back on the road again :D
"Get a proper bike!"
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Re: Eddie's 1100 Rebuild

Postby Eddie » 18 Jan 2018, 23:54

Picked up my new top yoke and torque arm etc from Pretech, lovely workmanship as usual I can recommend them if you need any fabrication work done. I'll post some pics soon.

Haven't done much else to it to be honest, I know shame on me!! ....my only excuse is I have lots of bits to paint but until the weather perks up a bit my workshops not warm enough!
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
86 Honda XL600R supermoto
73 Honda XL250 Motosport
79 Yamaha XT500
80 Honda Z50R Monkey
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Eddie
 
Posts: 66
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Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Postby Richard » 19 Jan 2018, 22:55

I do know that feeling, too cold to get some work done in the garage :( Looking forward to spring! At least double digits centigrade and no storms...
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