Eddie's 1100 Rebuild

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Eddie
Posts: 180
Joined: 28 Oct 2017, 19:46
Location: Reading Berkshire

Eddie's 1100 Rebuild

Post by Eddie »

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!!
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It's finally on the ramp
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cheers eddie
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
10 KTM 990 SMT
76 Yamaha XT500 supermoto
80 Honda Z50R Monkey
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Eddie
Posts: 180
Joined: 28 Oct 2017, 19:46
Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Post by Eddie »

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!
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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!!!
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The things we do hey!
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
10 KTM 990 SMT
76 Yamaha XT500 supermoto
80 Honda Z50R Monkey
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Eddie
Posts: 180
Joined: 28 Oct 2017, 19:46
Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Post by Eddie »

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.
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Cheers for now eddie
92 Kawasaki Zephyr 1100
78 Kawasaki Z1000a2
10 KTM 990 SMT
76 Yamaha XT500 supermoto
80 Honda Z50R Monkey
Swampy
Posts: 323
Joined: 04 Sep 2017, 18:01

Re: Eddie's 1100 Rebuild

Post by Swampy »

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 :)
Swamps :)
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Eddie
Posts: 180
Joined: 28 Oct 2017, 19:46
Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Post by Eddie »

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
10 KTM 990 SMT
76 Yamaha XT500 supermoto
80 Honda Z50R Monkey
Swampy
Posts: 323
Joined: 04 Sep 2017, 18:01

Re: Eddie's 1100 Rebuild

Post by Swampy »

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

Swamps :D
Swamps :)
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Eddie
Posts: 180
Joined: 28 Oct 2017, 19:46
Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Post by Eddie »

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
10 KTM 990 SMT
76 Yamaha XT500 supermoto
80 Honda Z50R Monkey
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HeavenEleven
Posts: 24
Joined: 05 Sep 2017, 21:11

Re: Eddie's 1100 Rebuild

Post by HeavenEleven »

Good work Eddie.

Looking forward to seeing him back on the road again :D
"Get a proper bike!"
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Eddie
Posts: 180
Joined: 28 Oct 2017, 19:46
Location: Reading Berkshire

Re: Eddie's 1100 Rebuild

Post by Eddie »

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
10 KTM 990 SMT
76 Yamaha XT500 supermoto
80 Honda Z50R Monkey
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Richard
Posts: 340
Joined: 24 Aug 2017, 14:35
Location: Zeewolde NL
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Re: Eddie's 1100 Rebuild

Post by Richard »

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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